Patent Publication Number: US-6712490-B2

Title: Framework for a lighting fixture

Description:
RELATED APPLICATIONS 
     This application claims the benefit of the filing date under 35 U.S.C. §119 of U.S. Provisional Application Serial No. 60/283,278 filed Apr. 11, 2001, the subject matter of which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to lighting fixtures and, more particularly, to chandelier frame members for holding decorative ornaments. 
     DESCRIPTION OF RELATED ART 
     A chandelier is typically formed of frame members from which a plurality of crystal or glass ornaments are suspended to provide an overall decorative appearance. The ornaments are typically attached to a metal wire having a hook at one end that passes loosely through a hole in the crystal and a hook at the other end that passes through a hole in the chandelier framework. In such an arrangement, the ornaments are supported solely by the wire and hang below the frame member. 
     Other chandelier designs include arrangements whereby individual crystals may be positioned at different angles. An example of such an arrangement is shown in U.S. Pat. No. 5,109,325. In this arrangement, one end of a chandelier hook is glued to the ornament. The other end of the hook is attached to the frame member with an engagement mechanism that allows the ornament to be put in a non-vertical position. 
     SUMMARY OF THE INVENTION 
     In one aspect the invention involves a series of chandeliers, lighting fixtures, and lighting fixture components. In one embodiment, a chandelier is disclosed comprising a cage having at least three substantially parallel rails and a plurality of ornaments contained within the cage, wherein a section of the rails defines an opening for inserting ornaments into the cage. 
     In another embodiment, a chandelier is disclosed comprising a plurality of longitudinal frame members including at least two substantially parallel rails, the frame members including a row of ornaments contained between and parallel to the at least two substantially parallel rails. 
     In another embodiment, an arm for supporting a candle light is disclosed. The arm comprises at least three substantially parallel rails held at a lateral distance from each other, a plurality of ornaments captured within the at least three substantially parallel rails, and a support element held by the rails and constructed and arranged to support a candle light. 
     In yet another embodiment, a lighting fixture is disclosed. The lighting fixture comprises a cage having at least three rails spaced at a lateral distance from each other for capturing decorative elements, the cage having a longitudinal direction, and decorative elements stacked within the cage, wherein the at least three rails restrain the decorative elements from substantial movement in a direction transverse to the longitudinal direction of the cage. 
     In another embodiment, an apparatus for holding decorative ornaments in a slidable configuration is disclosed. The apparatus comprises a lighting element, at least rails forming a cage, the cage capturing the decorative ornaments so that the decorative ornaments are not restricted by the cage from sliding freely along a longitudinal direction of the cage, the cage restraining the decorative ornaments from substantial movement in a direction transverse to the longitudinal direction of the cage. 
     In yet another embodiment, a chandelier is disclosed comprising a frame member having a cage, and ornaments, wherein the cage holds the ornaments and restricts the movement of the ornaments in a direction transverse to a longitudinal direction of the cage without there being attachments between the ornaments and the frame member. 
     In another embodiment, a chandelier is disclosed comprising a frame member having a longitudinal direction and containing ornaments, and means for restricting movement of the ornaments in a direction transverse to the longitudinal direction of the frame member without attachments between the ornaments and the frame member. 
     In another aspect, the invention involves a series of methods. In one embodiment, a method of manufacturing a frame member for a chandelier is disclosed comprising providing a cage having at least three rails and an opening, inserting a plurality of ornaments through the opening, and sliding the plurality of ornaments within the cage to desired positions to create a stack of ornaments in the cage. 
     In another embodiment, a method of manufacturing a chandelier is disclosed. The method comprises providing a cage formed with at least two rails extending in a longitudinal direction, stacking a plurality of decorative ornaments along the cage such that the ornaments contact at least two of the at least two rails, and the at least two of the at least two rails prevent the decorative ornaments from substantially moving in a direction transverse to the longitudinal direction. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     It should be understood that the drawings are provided for the purpose of illustration only and are not intended to define the limits of the invention. Various aspects of the present invention will become apparent with reference to the following detailed description taken in conjunction with the accompanying drawings in which: 
     FIG. 1 is a perspective view of a chandelier in accordance with one embodiment of the present invention; 
     FIG. 2 is a perspective view of a portion of a frame member assembly in accordance with one embodiment of the invention; 
     FIG. 3 is a cross-sectional view of the frame member assembly of FIG. 2; 
     FIG. 4 is front view of a frame member for a lighting fixture; 
     FIG. 5 is a front view of a frame member including a frame pattern in accordance with one embodiment of the invention; 
     FIG. 6 is a cross-sectional view of a frame member in accordance with one embodiment of the invention; 
     FIG. 7 is a front view of a portion of a frame member in accordance with one embodiment of the invention; 
     FIG. 8 is a cross-sectional view of a frame member assembly in accordance with another embodiment of the invention; 
     FIG. 9 is a cross-sectional view of a frame member assembly in accordance with another embodiment of the invention; 
     FIG. 10 is a perspective view of a frame member in accordance with yet another embodiment of the invention; 
     FIG. 11 is a cross-sectional view of a frame member assembly in accordance with another embodiment of the invention; 
     FIG. 12 is a perspective view of a frame member assembly in accordance with another embodiment of the invention; 
     FIG. 13 is a cross-sectional view of an alternative embodiment of the frame member assembly shown in FIG. 12; 
     FIG. 14 is a perspective view of a frame member assembly in accordance with yet another embodiment of the invention; 
     FIG.  15  and is a perspective view of a frame member assembly in accordance with another embodiment of the invention; and 
     FIG. 16 is a perspective view of an alternative embodiment of the frame member assembly shown in FIG.  15 . 
    
    
     DETAILED DESCRIPTION 
     In one illustrative embodiment in accordance with the invention, a lighting fixture, such as a chandelier, includes frame members that capture decorative ornaments, such as beads, crystals, glass, or other appropriate decorative ornaments for a lighting fixture. According to this aspect of the invention, the chandelier holds ornaments within the frame members, as opposed to suspending ornaments from frame members or attaching ornaments to the exterior of the frame members. Each frame member may be attached to the lighting fixture in at least one location and may form part of a support structure for other lighting fixture elements such as lights, bobeches, electric cords, and ornamental features other than those captured within the frame member. 
     The frame members may include substantially parallel rails that form a cage which holds the decorative ornaments. The cage and the decorative ornaments may be positioned and dimensioned such that the cage captures and supports the ornaments. In embodiments with thin and/or darkly colored rails, or transparent rails, such a lighting fixture may give the appearance of ornaments floating in midair, as if the decorative ornaments were supported by invisible frame members. In some embodiments, the decorative ornaments of the lighting fixture can be viewed from different angles without being substantially blocked by frame members. The frame members may also help to protect the ornaments from damage by surrounding them and securing them from movement. 
     The use of frame members having a cage for holding a plurality of beads may lessen or eliminate the need for wires that attach the beads to the frame member. The frame members may also maintain ornaments in a selected orientation without the use of connection or attachment elements to attach the ornaments to the frame members. Rails of the frame member may be configured to hold the ornaments in a selected orientation, and the frame members may be shaped in various decorative patterns. 
     Rails may also be used in combination with attachment wires to support decorative ornaments. For example, a string of beads may be supported on one side by two rails and attached to the frame member with a wire that runs through the center of the string of beads. Two rails may also be positioned on opposite longitudinal sides of a string of beads and substantially protect, support and/or hold the beads, while a wire also helps to hold the beads. Depending on the size of the rails, the beads may not be viewable from all angles in such a configuration. 
     It may be desirable to conceal electrical wires or other wires within the frame members of the lighting fixture. In this regard, in some embodiments the frame members may include rails which are made from tubes or other hollow elements. Electrical wires may then be run through the tubes to their destination, such as a lighting element. 
     According to another aspect of the invention, it may be desirable to form frame members with a reduced number of manufacturing operations. For example, a frame member having two longitudinal rails and cross-pieces may be manufactured by laser cutting piece of sheet metal and then performing secondary operations on the cross-pieces. In one example, holes may be drilled or punched in the cross-pieces, and in other examples, a hole may be initially cut in the cross-piece, and in a secondary operation, the cross-piece may be twisted. 
     An illustrative embodiment of a chandelier  2  shown in FIG. 1 includes frame members  10  arranged in a radial pattern around a center plate  15 , a center stem, or a center axis. Frame member  10  includes rails  18  which form a cage  25 . The rails  18  hold decorative ornaments such as beads  32  within the cage  25 . Other kinds of ornaments may be used, such as glass ornaments, crystals, listels, lights, light emitting diodes, colored stones, or any other kind of ornaments suitable for use with lighting fixtures. 
     In the embodiment shown in FIG. 1, the frame members are attached at a top of the chandelier  2  to a top center plate  20 , and at a bottom of the chandelier  2  to a bottom center plate  30 . The top center plate  20  and/or the bottom center plate  30  may be plates, discs or rings, or any other suitable connection plate. In some embodiments, covers  21 ,  31  are placed over or around the center plates  20 ,  30  to obscure the center plates  20 ,  30  from view. The frame members  10  extend radially outwardly from the center plate  15  and support lighting elements, such as candle lights  12 , and/or other features. Bobeches  14  or other cup decorations surround the base of the candle lights  12  and rosettes  28  are attached at various positions on the frame members  10 . Rosettes  28 , bobeches  14 , and other decorative pieces are not required, and may be of any suitable shape or configuration if present. 
     Frame member  10 , in addition to containing the beads  32  within the cage  25 , may hold other ornaments that are suspended or supported outside of the cage  25 . For example, a crystal may be suspended by a wire from one of the rails  18  or one of the rosettes  28 . 
     For purposes herein, the term “frame member” refers to any structure used to capture, hold, support or contain ornaments. A frame member does not need to contain or surround ornaments in order to be considered a frame member. In some embodiments, a frame member may provide structural support to the overall lighting fixture, but is not required to do so. 
     For purposes herein, the term “bead” refers to any ornament that is suitable for use in a chandelier or lighting fixture. Crystals used as ornaments may be cut crystals or molded crystals, or any other type of crystals known to one of skill in the art. The term “rail” is not limited to a specific length, cross-sectional shape, or material disclosed herein. 
     One embodiment of a portion of frame member  10  holding decorative beads  32  is shown in FIG.  2 . Four rails  18  form a cage  25  for holding beads  32 . The rails  18  are substantially parallel for holding beads  32  that are similar in size. The rails  18  are laterally spaced from each other such that the beads  32  can move freely along the cage  25  in a longitudinal direction. In this respect, the rails  18  may form a channel along which beads  32  may slide. The cage  25  is sized, however, such that the beads  32  cannot be removed from the cage  25  through the lateral spacing between the rails  18  without bending, moving or removing one of the rails  18 . In certain sections, the rails  18  may be spaced such that beads  32  within the cage  25  encounter significant friction when moved along the cage  25 . The cage  25  does not need to be smooth or continuous in that it may have indentations or scalloped sections which hold ornaments at selected locations. The rails  18  may be non-parallel for holding beads  32  of different shapes and sizes within the same cage  25 . For example, one section of the cage  25  may enclose a larger area and hold a larger bead  32  than another section of the same cage  25 . The cage  25  may narrow or expand either gradually or abruptly. 
     Certain of the beads  32  may be connected to each other with a wire such as a monofilament line or a steel wire to form bead strings. It is to be appreciated that beads  32  may be held together in bead strings or may be present separately within the frame members  10  without any attachments. When using eleven millimeter beads, each of the bead strings preferably includes twenty or fewer beads  32 . 
     FIG. 3 shows a cross-section of the portion of the frame member  10  shown in FIG.  2 . The four rails  18  capture and contain bead  32 , which, at its maximum diameter, substantially fills the cage  25 . The bead  32  may extend beyond the borders formed by the rails  18 . For example, a suitably sized bead  32  in the shape of a plus-sign (“+”) will be captured by the rails  18 , but will extend beyond the borders formed by the rails  18 . In the embodiment shown in FIG. 3, the bead  32  is held in a selected orientation by the rails  18 . Certain shapes of beads, such as a smooth spherically shaped bead, may not be maintained in a selected orientation by the rails  18 . In one embodiment, the rails  18  have a rectangular cross-section, but as may be appreciated by one of skill in the art, the cross-sectional shapes of the rails  18  may be square, rectangular, circular, triangular, or other. 
     FIG. 4 shows a frame member  10  containing a plurality of beads  32 . Frame member  10  includes rails  18  which contain beads  32 . Frame member  10  is shaped into a decorative pattern and rosettes  28  are attached to the frame member  10  at different locations. Cutouts  11  in the rails  18  allow for attachment to a connection element such as a top center plate  20  (FIG.  1 ). In this embodiment, a candle light  12  is held by a support element  23  attached to frame member  10 . The scrollwork pattern of this particular frame member  10  is designed to be displayed in a vertical orientation as shown, but may be displayed in one of many other orientations. Of course, frame member  10  may include other scrollwork patterns or designs. 
     FIG. 5 shows part of a frame portion  40  which may be used to form a portion of frame member  10  (FIG.  1 ). In a preferred embodiment, two frame portions  40  are cut from sheet metal using a laser cutting machine and are connected to form frame member  10 . As will be evident to one of skill in the art, frame portions  40  may be made from any suitable material and with any suitable manufacturing process. Frame portion connectors  38 ,  39  are used to attach two frame portions  40  together to form a frame member  10 . Frame portion connectors  38 ,  39  also interconnect sections of rails  18  within the same frame portion  40 . The frame member  10  is attached to center plate  15 , but may be attached to other frame members or other lighting fixture elements. It is to be appreciated that frame member  10  need not be comprised of frame portions  40 . In some embodiments, rails  18  may be separately constructed and attached together. 
     In one embodiment, two frame portions  40  are attached with spacers  42  as shown in FIG.  6 . FIG. 6 is a cross-sectional view along A—A of FIG. 5 with the addition of an attachment assembly. The spacers  42  help provide structural support to the frame member  10  (FIG. 1) such as by stiffening the rails  18  so that the rails  18  do not get pushed together and damage the beads  32 . The spacers  42  may be any suitable shape and made from any suitable material. Rosettes  28  or other cover elements may be used to obscure the spacer  42  from view. Rosettes  28  may also be used to help attach the frame portions  40  (FIG. 5) to one another such that the rails  18  do not spread apart and allow beads  32  to escape. For example, a wire  45 , such as a steel wire or string, may be attached to a first rosette  28 , inserted through a passageway  52  in the spacer  42 , and attached to a second rosette  29 . Other methods of securing frame portions  40  together will be apparent to one of skill in the art. 
     FIG. 7 shows an insertion opening  50  in the frame portion  40  to allow for insertion of beads into the cage. In this illustrative embodiment, the separation between two of the rails  18  is slightly greater toward one end to form the insertion opening  50 . In another embodiment, one of the rails  18  may be thinner toward one end, thereby forming the insertion opening  50 . Insertion opening  50  is preferably one and a half bead diameters in length to facilitate insertion of the beads, but any suitable length or transverse size may be used. Insertion openings  50  may be located at any number of locations and are not restricted to the ends of frame portions  40 . 
     Once the beads are inserted, two rosettes  28  and  29  are placed on either side of the frame member and attached through passageway  52 , as shown in FIG. 6, so that the rosette  28  covers the insertion opening  50  to prevent the beads from exiting the cage. Rosettes  28  and  29  may be attached to frame member  10  by a string, wire, screw, a nut and bolt arrangement, an adhesive, or by any other suitable manner. It is to be appreciated that rosettes  28  and  29  do not need to be placed over every insertion opening  50 , and other structures or methods may be used to contain the beads once they have been inserted. For example, a bead slightly larger than the insertion opening  50  may be squeeze-fit into the cage so that it obstructs the insertion opening  50 . A bead that is asymmetric may be inserted into the insertion opening  50  in one orientation, and then reoriented so that it obstructs the opening  50 . An extra rail or pivoting flap may be employed to obstruct the insertion opening  50 . The flap may be hinged on the inside of the cage so that it opens inwardly to allow insertion of beads, and positioned so that it does not open outwardly, thereby preventing beads from exiting the cage. Insertion openings  50  are preferably positioned throughout the frame member  10  such that bead strings need not be more than twenty beads in length. As will be evident to one of skill in the art, the preferred maximum bead string length may vary with the size, shape and tolerances of the beads. In alternative embodiments, where bead strings are longer or shorter than twenty beads, insertion openings  50  may be positioned further apart or closer together. 
     Other arrangements for the insertion of beads into the cage are contemplated. For example, the rails may be constructed such that they are flexible enough to allow for beads to be inserted at a midpoint between two frame pattern connectors by snap fitting the beads into the cage (not shown). In such an embodiment, the rails return to their original positions and contain the beads after a bead is inserted into the cage. 
     Another alternative arrangement for inserting beads includes a rail that is detachably secured at one end to another rail or a connection plate (not shown). The rail may be detached at one end and pivoted away from the other rails, allowing beads or bead string to be inserted. Once beads are inserted, the rail is re-attached to the connection plate or other rails, and the beads are contained within the frame member. In some embodiments, beads or other ornaments may also be inserted at an end of the cage before the frame member is attached to a connection plate. 
     While in a some embodiments the beads  32  are stacked end-to-end in a single file as illustrated in FIG. 2, the beads  32  may also be held side-by-side or stacked in different arrangements. For example, as shown in a cross-sectional view in FIG. 8, a fifth rail  22  could be added to the interior of the cage  25  (FIG. 2) to form two triangular cages  26 , wherein each triangular cage  26  is made up of two rails  18  and a shared third rail  22 . Six rails  18  could be used to form two square cages  27 , as shown in FIG.  9 . Nine rails could be used to form four cages in a two by two pattern (not shown). Spherical beads within adjacent cages can be positioned directly adjacent one another, or they can be offset longitudinally to allow for a closer fit. 
     It is to be appreciated that the rails  18  are not required to be separate members. For example, in other embodiments (not shown), a cylinder or an ornament channel formed with panels may be used to hold ornaments and may include cutouts, holes or slots for viewing the ornaments. In some embodiments, rails  18  may not be parallel to one another at various cross-sectional locations, but may nevertheless be substantially parallel along a length of frame member  10 . For instance, frame member  10  may include four rails  18  that are each formed in a zig-zag pattern and slightly offset longitudinally from one another. In such an embodiment, a short section of two rails  18  may not be parallel, but along a longer length of frame member  10 , the two rails  18  may be substantially parallel. A cage can be a raceway, that is, a longitudinal path for sliding ornaments. In some embodiments, two rails  18  can form a raceway. 
     In another illustrative embodiment, a cage may be formed with two rails  18  as shown in FIG.  10 . The beads  132  are molded to have slots  35  that receive rails  18 . The beads  132  are placed on the rails  18  at the ends of the rails, or in some embodiments, the beads  132  may have snap-fit slots that attach to the rails  18 . 
     Certain shapes of crystals, glass, or beads may be held between two rails  18  without slots  35 . FIG. 11 shows an example of a shaped ornament  36  that can be captured between two rails  18 . Shaped ornament  36  has a top groove  58  and a bottom groove  59  which allow the rails  18  to restrict movement of the shaped ornament  36  in a direction transverse to the longitudinal direction of the rails  18 . In this embodiment, the ornaments may be added at the longitudinal end of the rails  18  and slid along the raceway to a selected position. The frame members and the ornaments may be dimensioned such that the ornaments can be inserted from a lateral direction into the raceway in one orientation and then turned such that they are secured by the frame member. Additional ornaments may then be stacked to fill the length of the raceway and maintain the orientation of the ornaments. 
     To facilitate the running and/or concealment of wires such as electric power wires, a frame member  10  may be configured with rails  18  that are tubes, as illustrated by way of example in FIG.  12 . In such a configuration, an electric wire (not shown) may be hidden from view along its path of travel by passing it through the interior of rail  18 . Brackets  60  may be used to connect the rails  18  together by spotwelding a bracket  60  to each rail  18 , although any suitable method of connecting the rails  18  may be employed. The brackets  60  may have holes  62  through which wire such as steel wire or monofilament line may be passed to help maintain the position of a bead string. Having the holes  62  configured to be parallel to the bead strings may be particularly advantageous for attaching bead strings to the frame member  10 . In this regard, an end of a wire may be passed through the hole  62  and tied into a retaining knot. Similarly, an end of a monofilament line may be passed through the hole  62  and melted to produce a retaining bead. 
     The location of the beads  32  is not limited to one side of the frame member  10 . For example, beads  32  may be held on both sides of the frame member via a combination of the rails  18  and the monofilament line or wire, as shown by way of example in FIG.  13 . In this configuration, a single bracket  60  having two holes  62  may be used to connect the rails  18 , or two brackets  62  may be used. 
     It is to be appreciated that use of the tubes as rails is not limited to round tubes such as the ones shown in FIG.  12 . For example, rails  18  formed with square tubes may be provided as shown in FIG.  14 . In this embodiment, the rails  18  are connected with brackets  60  which have ears  64  bent at a 90 degree angle to the brackets  60 . The ears  64  are welded to the rails  18  and may be configured such that a monofilament line or wire of a bead string can be placed into the bracket  60  via a slot  66 . The bracket  60  may then be pressed in direction  68  to deform the bracket and close the slot  66  so that the monofilament line or wire is captured. It is to be understood that other methods of connecting the rails  18  or retaining the monofilament line may be employed. 
     As described above, two rails  18  may be used to capture and/or support beads  32 . In one embodiment, instead of using brackets to connect two rails  18 , the rails  18  are formed as one integral piece. FIG. 15 shows a laser-cut frame member  10  that is configured to retain beads  32 . Cross-pieces  70  integral to the frame member  10  connect the rails  18 . The cross-pieces  70  may be provided with holes  62  for retaining the monofilament line. The holes  62  may be punched holes or may be holes provided by another suitable method such as drilling. 
     In another embodiment, an example of which is shown in FIG. 16, an integral frame member  10  that does not require a secondary operation for forming a hole  62  is provided. In this embodiment, the frame member  10  is laser-cut and includes cross-pieces  70  with holes  62  that are also laser-cut. The cross-pieces  70  are then twisted 90 degrees so that the holes  62  are parallel with the bead strings. 
     The chandelier  2  may be made in any suitable manner. The frame portions  40  may be laser-cut from sheet material such as stainless steel, mild steel, or other suitable material. The frame portions  40  may be joined with spacers, wires, ferrules, adhesive, or nuts and bolts. The frame members  10  or frame portions  40  may be formed with one piece of material bent into a selected shape. The individual frame members  10  may be attached together or attached to a connection element. Electric cords may run along the interior or the exterior of the frame members, or within the rails  18  themselves. 
     Having described particular embodiments of the invention in detail, various modifications and improvements will readily occur to those skilled in the art. Such modifications and improvements are intended to be part of this disclosure and within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only and the invention is defined by the following claims and their equivalents.