Patent Publication Number: US-2019178475-A1

Title: Electric Recessible Track Assembly and Method of Installation in Standard 5/8-inch Thick Drywall

Description:
RELATED APPLICATIONS 
     This application is a continuation application of U.S. patent application Ser. No. 15/838,616 titled “Electric Recessible Track Assembly and Method of Installation in Standard ⅝-inch Thick Drywall” and filed Dec. 12, 2017, now U.S. Pat. No. ______. The &#39;616 application is hereby incorporated by reference. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     The present invention relates to track lighting and recessed lighting. Specifically, the invention relates to a method and system for recessing track lighting into a drywall surface, such as a ceiling or wall. Most specifically, installation of the disclosed system is in standard ⅝-inch thick drywall. 
     BACKGROUND OF THE INVENTION 
     Lighting is an important feature when designing work or living space. However, it is not enough that the lighting provides sufficient illumination to an area. The lighting fixtures have an aesthetic function as well. Two common permanent lighting fixtures are known as track lighting and recessed lighting. 
     Track lighting is a method of lighting where light fixtures are attached anywhere on a continuous track device which contains electrical conductors. This is in contrast to directly routing electrical wiring to individual light positions. Tracks are either mounted to ceilings or walls, lengthwise down beams, or crosswise across rafters or joists. They can also be hung with rods from especially high places like vaulted ceilings. 
     Typical systems have line voltage running through a track. The track may have more than one live conductor, so that multiple switched circuits can be used to control different lights on the same track. This feature allows light fixtures to be maneuvered to any position along the continuous track, as needed or desired. However, the visible track has drawbacks when the aesthetics are important. Also, if a surface with track lighting is being painted, the track needs to be removed entirely. 
     Recessed lights (aka, downlights, can (or canister) lights) are different than track lighting in that they are installed into a hollow opening—usually round—in a ceiling. When installed, it appears that light is shining from a hole in the ceiling, concentrating the light in a downward direction as a broad floodlight or narrow spotlight. Typically, little if any of the actual light fixture is observable. 
     However, recessed lights are fixed light sources which cannot be readily moved without some skilled electrical re-wiring and surface patching. Another drawback is recessing the lights requires that either the lights be positioned either joists or the joist must be notched or altered in some way to accommodate the light. The cutting of ceiling joists is an undesirable option in many cases. 
     The present invention provides a lighting system without the aesthetic drawbacks of track lighting and without the lighting and installation limitations of standard recessed lights. By combining only the useful features of both systems into a single device, lighting aesthetics, changeability, and adjustability are improved. The present lighting system can be installed without exposure of unsightly brackets and tracks and without the need to notch or otherwise altering existing studs or joists. 
     Until the invention of the present application, these and other problems in the prior art went either unnoticed or unsolved by those skilled in the art. The present invention provides a lighting track system which is capable of multiple configurations with the associated light fixtures without sacrificing design, style or affordability. 
     SUMMARY OF THE INVENTION 
     There is disclosed herein an improved track lighting system and assembly which avoid the disadvantages of prior devices while affording additional structural and operating advantages. A recessible electric track, track assembly and recessed electric track construction method are described in such detail that a person of reasonable skill in the art could make and use these inventions. 
     Generally speaking, the recessible electric track comprises a section of extruded track defined by a channel having first and second opposing sidewalls, a base wall, and a longitudinal opening opposite the base wall. The channel has a depth which is no more than the thickness of standard ⅝ inch drywall. 
     Within the channel there is a first bus rod extending the length of the track section and secured to the first sidewall, and a second bus rod extending the length of the track and secured to the second sidewall. Adjacent to the opening of the channel is a first lateral flange extending from an exterior of the first sidewall substantially parallel to the base wall, and a second lateral flange extending from an exterior of the second sidewall substantially parallel to the base wall. The flanges allow the track to be attached to a surface while having the channel recessed in the surface. The first and second bus rods are coupled to one of either an AC or DC power source so as to conduct electricity within the channel. 
     In a specific embodiment, the track is preferably dimensioned to fit within the depth of standard drywall boards (i.e., ⅝ inch). Further, the electric track system comprises a first bus rod carrier and a second bus rod carrier which are used to secure the first and second bus rods within the channel. The carriers preferably slidably mount within corresponding grooves on the interior of the channel sidewalls. 
     In another specific embodiment, the electric track system further comprises first and second fixture retention channels formed on an interior surface of the first and second sidewalls, respectively. At least one light fixture can be slidably engaged within the first and second fixture retention channels to be powered by the bus rods. Additionally, the first and second lateral flanges are configured to attach to a surface and textured to allow concealment by taping and a joint compound. 
     In a preferred embodiment, the electric track system further comprises a channel cover slidably mounted to the section of track to cover at least a length of the longitudinal opening. 
     A track lighting system is also described and comprises a section of extruded track comprising a channel having first and second opposing sidewalls, a base wall, and a longitudinal opening opposite the base wall, a first lateral flange extending laterally from an exterior of the first sidewall substantially parallel to the base wall and for at least a portion of the length of the track, and a second lateral flange extending from an exterior of the second sidewall substantially parallel to the base wall and for at least a portion of the length of the track. The lighting system also comprises a first bus rod secured within the channel to the first sidewall, a second bus rod secured within the channel to the second sidewall, at least one light fixture having a base slidably retained within the channel and covering a portion of the longitudinal opening, the base having contacts electrically engaged with the first and second bus rods, and a channel cover slidably mounted to the section of extruded track to cover a portion of the longitudinal opening not covered by the at least one light fixture. The first and second bus rods are coupled to one of either an AC or DC power source and the first and second lateral flanges are secured to a surface such that the channel is recessed within the surface. 
     Finally, a method for recessing track lighting is also described herein. Generally, the method comprises the steps of providing a predefined length of an embodiment of the electric track described above, creating an opening defined within a surface, placing the channel of the electric track within the opening, securing the first and second lateral flanges to the surface to retain the channel within the opening, mounting a light fixture within the electric track so that contacts on the fixture engage the first and second bus rods, and then supplying electricity to the first and second bus rods to activate a light within the light fixture. 
     These and other aspects of the invention may be understood more readily from the following description and the appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings, embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated. 
         FIG. 1  is a perspective view of typical prior art track lighting attached to a ceiling; 
         FIG. 2  is a perspective view of three typical prior art recessed (or can) lights in a ceiling; 
         FIG. 3  is an exploded view of an embodiment of a track assembly for creating recessed track lighting in accordance with the present disclosure; 
         FIG. 4  is an end view of an embodiment of the constructed electric track assembly shown in  FIG. 3 ; 
         FIG. 5  is a side view of the constructed track assembly of  FIG. 4 ; 
         FIG. 6  is an illustration of an embodiment of a length of the track assembly, including two lighting fixtures, being placed within an opening of a surface, such as a ceiling; 
         FIG. 7  is a side cross section of the embodiment of the track assembly of  FIG. 6  showing the assembly secured within the surface; 
         FIG. 8A  is an end cross section of an embodiment of the track assembly illustrating fastening the lateral flanges through the surface to a stud or joist with the channel recessed; 
         FIG. 8B  is an end cross section of an embodiment of the track assembly illustrating fastening the lateral flanges through the surface to a perforated metal strap with the channel recessed; 
         FIG. 9  is a perspective view of an embodiment of a lighting fixture secured within the channel of an embodiment of the track assembly; 
         FIG. 10  is close up cross section showing the base portion of the lighting fixture illustrated in  FIG. 9 ; 
         FIG. 11  is close up showing a connection between a bus rod and a contact on the base of the lighting fixture of  FIG. 9 ; 
         FIG. 12  is another close-up cross section of the track assembly with lighting fixture of  FIG. 9 ; 
         FIG. 13  is a top view of an alternate embodiment of the track assembly showing decorative flanges; and 
         FIG. 14  is a cross section of an alternate embodiment of the track assembly having decorative flanges. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail at least one preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to any of the specific embodiments illustrated. 
     With reference to the lighting systems of  FIGS. 1 and 2 , a standard track lighting system and recessed lighting can be seen. The benefits of the present assembly and method over these prior art systems are significant. The track lighting system  100  of  FIG. 1  allows the two light fixtures to be moved along the track to desired positions. However, the system  100  lacks favorable aesthetics, due to its exposed industrial-like track, and provides an obstacle to painting. Further, adding a third light fixture, or replacing one of the two existing fixtures, involves potential complicated wiring issues. The recessed lights  101  of  FIG. 2 , while considered to be more aesthetically-pleasing, with most of the structure being concealed, have considerable drawbacks with respect to actual lighting functionality. The recessed lights  101  illuminate straight down with no ability to move to change lighting emphasis. Similar to the track lighting, the addition or removal of a recessed light fixture can be quite involved. 
     Referring now to  FIGS. 3-12 , there is illustrated a recessible track lighting system, generally designated by the numeral  10 . Generally speaking, the system  10  is comprised of a section of extruded track  12  having first and second bus rods  14 A,  14 B mounted inside the track with lateral flanges  16 A,  16 B on the exterior for mounting purposes. As will be described in further detail below, the track  12  is configured to be mounted within an opening on a surface  50  and connected to a proper AC or DC power source (not shown). Light fixtures  40  can then be readily added to, moved, and removed from the system  10  without complicated wiring issues. 
     An exploded view of an embodiment is shown in  FIG. 3 , with an end view in  FIG. 4  and a side view in  FIG. 5 . The extruded track  12  is preferably cut into lengths and includes a channel  20  defined by two opposing sidewalls  22 A, B and a base wall  24 , with an opening  26  opposite the base wall  24 . The lengths of track  12  can be connected end-to-end to achieve extended lengths. In specific embodiments, the material of the track  12  can be curved (not shown) to allow more creative recessed lighting systems  10 . In all embodiments, the channel  20  has a depth of no more than the standard construction drywall thickness of ⅝ inches. This allows the track  12  to pass over studs and joists  60  (e.g., see  FIGS. 6, 7, 8A and 8B ). 
     A first bus rod  14 A extends the length of the track section  12  and is secured within the channel  20  to a sidewall  22 A. A second bus rod  14 B also extends the length of the track  12  and is secured within the channel  20  to the opposite sidewall  22 B. The lateral flanges  16 A, B extend from an exterior of the sidewalls  22 , preferably along a top edge, as shown best in  FIG. 4 . The flanges  16  may run the entire length of the track  12  or only portions of the track  12  if desired. 
     As noted above, the track  12  is dimensioned to be retrofit within an existing wall or ceiling. That is, regardless of the positioning and length of track  12 , the track  12  will not require alteration of wall studs or ceiling joists  60  to accommodate system  10 . The depth of the channel  20  is such that it is substantially flush with standard ⅝ inch drywall when recessed (see  FIG. 8 ), as explained in greater detail below. 
     The bus rods  14  are preferably secured within carriers  28  A, B. The carriers  28  are comprised of an insulating material and are configured to slide into grooves  30  positioned on an interior surface of the sidewalls  22 . The distance between the two bus rods  14  should provide a gap into which a lighting fixture base  42  ( FIGS. 10-12 ) may slide through while maintaining contact with the bus rods  14 . A channel cover  32  is preferably used to cover the channel opening  26 . The cover  32  is preferably configured to slide onto the opening  26  from either end of the track  12  or may be made to snap-fit over the opening  26 . However, where lighting fixtures  40  are positioned in and extend from the channel  20 , the channel cover  32  may cover only the uncovered portions of the opening  26 . 
     With reference to  FIGS. 9-12 , a fixture retention channel  34  is formed in the track channel  20  between the sidewalls  22  A, B just below the opening  26 , as shown in  FIG. 4 . The retention channel  34  runs the length of the track  12  and allows a light fixture  40  to be retained on the track  12 . More importantly, the bus carriers  28  A, B are secured to the sidewalls  22  just below the fixture retention channel  34  with the bus rods  14  A, B facing inward and partially exposed. As previously noted, the gap created between the bus rods  14  allows a base  42  of the light fixture  40  to maintain contact with the bus rods  14  to power the light fixture  40 . Preferably the bus rods  14  are hard-wired to an AC or DC power source. 
     Installation of the recessed track lighting assembly  10  is illustrated in  FIGS. 6-8 . Once the assembly  10  is properly prepared (preferably without the light fixtures  40  connected), it may be inserted into an opening in a surface  50 , such as a ceiling. Connection of the power cord to the power source may be required before insertion of the assembly  10 . The opening should be cut into an existing surface  50  so as to allow only the channel  20  of the assembly  10  to fit into the opening with the flanges  16  A, B abutting an exterior of the surface, as shown in  FIGS. 7, 8A and 8B . A fastener groove  36  may be constructed into each flange  16 , preferably along a midline. Fasteners  38 , such as screws or finishing nails, may be used to secure the assembly in place. 
       FIGS. 6, 7 and 8A  illustrate the track  12  being installed to cross over an existing wall stud or ceiling joist  60 . While the embodiment illustrates a perpendicular orientation to the stud  60 , it may be placed into a surface  50  to cross at any angle to the stud  60 . For a most secure installation, it is preferred that fasteners  38  pass through flange  16 , surface  50  and into a stud  60 . 
     Where the track  12  runs parallel to a stud  60 , as shown in  FIG. 8B , a perforated metal mounting strap  62  may be secured across a backside of the opening  26  using fasteners  64 , preferably every 32 inches. The straps  62  have a plurality of holes therein so that the fasteners  38  are sure to encounter a hole as they pass through the drywall surface  50 . The straps  62  provide additional support to the system  10  where studs and joist  60  are not present. 
     Once secured, the textured surfaces of the flanges  16  A, B will allow concealment of at least portions of the recessed track  12  using joint tape and joint compound. In preferred embodiments, light fixtures  40  are intended to extend above the channel  20  so only the flanges  16  A,B need be concealed. That is, the channel opening  26  should remain accessible after final installation. Accordingly, once the surface  50  is painted and dry—including the covered flanges—at least one lighting fixture  40  can be added to the assembly  10 . Additional fixtures can be added to the recessed track assembly  10  as needed and removed when no longer desired. A channel cover  32  may be added between fixtures  40 , if desired. 
     By “joint compound” and “wall compound” it is meant that any material used on a surface to cover, conceal or even decorate any portion of the surface. Typically, the material includes a perforated tape and a compound widely referred to in the industry as “mud.” However, the term concealing material may also include textured paints, wall paper, millwork or other such materials appropriate for the desired aesthetic effect. 
     In an alternate embodiment shown in  FIGS. 13 and 14 , the lateral flanges  16 ′A and  16 ′B include a decorative finish. The flanges  16 ′A/B are preferably decoratively-shaped and may be electroplated or powder-coated to achieve a desired finish and color. As such, the flanges  16 ′A/B would not be covered by a concealing material. 
     The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants&#39; contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.