Patent Publication Number: US-8540405-B1

Title: Systems, methods, and devices for installing light fixtures

Description:
TECHNICAL FIELD 
     The technical field of the exemplary embodiments relates generally to lighting solutions, and more particularly to systems, methods, and devices for installing light fixtures. 
     SUMMARY 
     According to an exemplary embodiment of the invention, there is disclosed a light fixture providing improved installation features. The light fixture may include a light fixture housing that forms a cavity and has a first end and second end, and a connection means (e.g., nut and bolt, screw, nail, adhesive, magnet, or other fastener) located at either the first end or second end of the housing, where the connection means connects the light fixture housing to another light fixture housing. The light fixture further includes a bendable light tray located in the cavity of the light fixture housing below the connection means. 
     In accordance with one aspect of the invention, the light tray shields the connection means from view from below the light fixture housing. In accordance with another embodiment of the invention, the light tray includes at least one lamp socket. According to another aspect of the invention, the light tray is L-shaped. In accordance with yet another embodiment of the invention, at least one lamp socket is located at one end of the L-shaped light tray. According to another aspect of the invention, the housing is a linear housing. In accordance with yet another embodiment of the invention, the connection means includes a nut and bolt. According to another aspect of the invention, the housing includes a bulkhead associated with the connection means. In accordance with yet another embodiment of the invention, the light tray includes at least one aperture for securing the light tray to the fixture housing. According to another aspect of the invention, the housing includes an alignment pin for aligning the housing with a second light fixture housing. 
     In accordance with another exemplary embodiment of the invention, there is disclosed a method for connecting two linear light fixtures that includes aligning a first end of a first fixture housing with a second end of a second fixture housing, and bending a light tray located in the first fixture housing such that the bending of the light tray exposes at least a portion of a bulkhead of the first fixture housing. The method includes connecting the first fixture housing with the second fixture housing through the use of a fastener associated with the bulkhead of the first fixture housing, and after connecting the first fixture housing with the second fixture housing, bending the light tray such that at least a portion of the light tray covers at least a portion of the bulkhead of the first fixture housing. 
     According to one aspect of the invention, the method may further include connecting a light source to a socket located on the light tray. In accordance with another aspect of the invention, aligning the first end of the first fixture housing with the second end of the second fixture housing includes using at least one alignment pin located at the first end of the first fixture housing engaging with the second end of the second fixture housing. According to yet another aspect of the invention, bending a light tray to expose a bulkhead of the first fixture housing located in the first fixture housing includes bending a light tray at a perforated bend point. In accordance with another aspect of the invention, bending the light tray to cover at least a portion of the bulkhead includes covering at least a portion of the fastener with the light tray. According to yet another aspect of the invention, connecting the first fixture housing with the second fixture housing through the use of a fastener associated with the bulkhead of the first fixture housing includes connecting the fastener with another bulkhead located in the second fixture housing. 
     In accordance with another aspect of the invention, connecting the first fixture housing with the second fixture housing through the use of a fastener associated with the bulkhead of the first fixture housing includes connecting the first fixture housing with the second fixture housing a bolt and nut as the fastener. According to yet another aspect of the invention, bending the light tray to cover at least a portion of the bulkhead further includes aligning the light tray of the first fixture housing with another light tray of the second fixture housing such that a first socket associated with the light tray of the first fixture housing is aligned with a second socket associated with the light tray of the second fixture housing. In accordance with another aspect of the invention, the method may further include securing the light tray to the first fixture housing. According to yet another aspect of the invention, securing the light tray to the first fixture housing includes driving a screw through an aperture located on the light tray. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIGS. 1A and 1B  illustrate the connection point between two light fixtures and bendable light trays providing access to the connection means for joining the two light fixtures in accordance with an example embodiment. 
         FIG. 2  illustrates bendable light trays during installation in accordance with an example embodiment. 
         FIG. 3  illustrates light trays used for connecting two linear light fixtures in the installed position in accordance with one example embodiment. 
         FIG. 4  presents a flowchart describing a process for the installing a light fixture using the bendable light tray in accordance with one example embodiment. 
         FIG. 5  illustrates an example light tray located at one end of a light fixture in the installed position in accordance with one example embodiment. 
         FIG. 6  illustrates an example light tray located at one end of a light fixture in the open position in accordance with one example embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     Light fixtures are sometimes installed in long linear runs along or suspended from a ceiling. During installation, the installer often has to install light fixtures that abut each other. Embodiments of the invention described herein are directed to the use of bendable light trays in light fixtures that allow an installer of the light fixture to bend the trays during installation to provide quick and easy access to the installation features of the light fixture during the installation process. The systems and methods described herein may provide several advantages including the ability to gain access to the inside of a light fixture without having to remove parts for installation of the fixture. The systems, methods, and apparatuses described herein may also provide easier installation methods for joining fixture sections into continuous runs and/or hanging fixtures into sheetrock. 
     Embodiments of the invention now will be described more fully hereinafter with reference to the accompanying drawings, in which example embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like, but not necessarily identical, elements throughout. 
       FIGS. 1A and 1B  illustrate the connection point between two light fixtures and bendable light trays providing access to the connection means for joining the two light fixtures in accordance with an example embodiment. As shown in  FIG. 1A , an end section of a light fixture housing  105  is being aligned with the end section of another light fixture housing  110  during the installation of one or both of the light fixtures. During the alignment process, aligner pins  130  may be used at the end of one light fixture to align both light fixtures and to allow for a substantially flush and/or contiguous installation of both fixtures. A member (e.g., bulkhead, plate, or bracket)  120  and a fastener  125  are located on the interior of the end of the first light fixture  110 . The fastener  125  may be a carriage bolt and joiner nut or another fastener means such as a nail, screw, or the like. In one exemplary embodiment, the fastener  125  is disposed through an opening in the bulkhead  120 . 
     Adjacent to the bulkhead  120  is a connector  140  located on the back wall of the fixture housing for connecting the housing to the ceiling or suspension system. In the example embodiment shown in  FIGS. 1A and 1B , a light tray  115  is located on the interior of the light fixture housing below the bulkhead  120  (i.e., in front of the bulkhead  120  hiding it from view when looking up into the fixture housing from below). The light tray  115  may be shaped in a variety of different ways so as to fit within the fixture housing and/or shield the connector  140  from view from below the fixture. Additionally, other light fixture features, such as a socket  135 , mounting apertures, etc. may be incorporated in or connected to the light tray  115 . In the example embodiment shown in  FIGS. 1A and 1B , the light tray  115  may be L-shaped and include a socket  135  for connecting to a light source such as a lamp, bulb, or LED module. The light tray  115  may be constructed from any material that allows for the light tray  115  to bend, such as sheet metal, plastic or another malleable and/or hand-bendable material.  FIG. 1B  shows a closer view of the bendable light trays  115  providing access to the connection means for joining two light fixtures shown in  FIG. 1A . 
       FIG. 2  illustrates bendable light trays during installation in accordance with an example embodiment. In the example embodiment shown in  FIG. 2 , the light tray  215  of a first fixture  205  is bent back to reveal and allow access to the fixture bulkhead  225 . At this point in the installation process, a fastener  230 , such as the nut and bolt shown in  FIG. 2 , may be used to align and connect one fixture bulkhead  225  to the bulkhead  240  of an adjacent light fixture (or light fixture section)  210 . As shown in  FIG. 2 , the light tray of the second light fixture  210  is also bent back to allow access to the bulkhead  240 . Also shown in  FIG. 2 , is a light source  235  such as a lamp, bulb, LED module or the like that may be installed in front of the light tray, for example, once the installation process is completed and the light tray  215  is bent back into place. 
       FIG. 3  illustrates light trays  305 , used for connecting two linear light fixtures, in the installed position in accordance with one example embodiment. As shown in the example embodiment of  FIG. 3 , the L-shaped light tray  305  of one fixture is aligned with the L-shaped light tray  305  of another fixture such that the sockets contained on each light tray  305  are aligned or substantially aligned. In one example embodiment, the light trays  305  are shaped in complimentary or corresponding shapes (e.g., male-female corresponding shapes, puzzle piece-like fit, etc.). During installation, once the light trays  305  are folded down and aligned, they may be held in place by a fastener  310  such as a screw through an aperture in the light tray  305  for connecting the light tray  305  to the housing or another connection means such as a nail, adhesive, magnet, or the like. In the example embodiment of  FIG. 3 , the bend points  315  are perforated (i.e., in one example embodiment, the bend points may be the segments between such perforations), thereby only allowing for a limited number of bends before the light tray  305  would snap off at the bend points  315 . In example embodiments the perforations between the bend points  315  of the light tray  305  may be rectangular slots or another shaped aperture, such as, for example, round, square, triangular, obround, a slot, a slot and obround. The size of the apertures may be of a variety of lengths and widths so long as the light tray may bend out to expose the connection means for installation as well as bend back into place to at least partially cover the connection means during and/or after installation of the light fixture. 
       FIG. 4  presents a flowchart  400  describing a process for the installing a light fixture using the bendable light tray in accordance with one example embodiment. Referring now to  FIGS. 1-4 , the example process  400  begins at block  405  where the fixture is positioned for installation. In example embodiments, the fixture may be located on the room-side of a ceiling or wall, recessed into the ceiling or wall, or suspended from a ceiling or wall. The fixture may also be aligned with another light fixture (or another section of the same light fixture) to allow for a continuous run of light fixture housings and/or continuous light emitted from the fixtures. 
     Next, block  410  is invoked where the bendable light tray located on the interior of the light fixture is bended (or folded) back to reveal the connection point(s) for the light fixture housing and/or the fastener(s) for connecting two light fixtures (or light fixture sections) to one another. The installer then installs the fixture and/or connects the fixture to another adjacent fixture (or section) using the connection method provided behind the light tray in block  415 . In one example embodiment, during installation, a nut and bolt on the bulkhead may be used as the connection means and may also pull two adjacent fixtures together as part of the connection process to provide a flush connection and/or consistent or continuous segments of light emitted by both light fixtures. Next, block  420  is invoked where the light tray is bent back into place to continue (or complete) installation of the fixture. In the example installation method of  FIG. 4 , block  425  may then be invoked where the light source, such as a lamp, bulb, LED module, etc. may then be installed in the fixture. 
       FIG. 5  illustrates an example light tray  500  having an alternative shape and located at one end of a light fixture, in the installed position in accordance with one embodiment.  FIG. 6  illustrates an example light tray  600  having an alternative shape and located at one end of a light fixture, in the open position in accordance with one embodiment. The light trays shown in  FIGS. 5 and 6  are examples of light trays that are not L-shaped. Additionally the light trays shown in  FIGS. 5 and 6  are located at the end of a light fixture that does not connect to another light fixture (or light fixture section). As shown in the embodiment of  FIG. 6 , the light tray  600  has a bendable range of anywhere between 30 and 180 degrees and preferably at least 90 degrees from its installed position to allow access behind the light tray  600  during installation. 
     Accordingly, many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of this application. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.