Patent Publication Number: US-7708420-B2

Title: Light fixture

Description:
This Application claims priority under 35 U.S.C. 119(e) to U.S. Provisional Application Ser. No. 60/877,938 filed on Dec. 29, 2006 which is incorporated by reference. 

   FIELD OF THE INVENTION 
   The present invention relates to a light fixture, and more particularly to a light fixture configured to be flush mounted on a surface. 
   BACKGROUND OF THE INVENTION 
   It is known to provide light fixtures for use in marine environments or other similar environments wherein moisture is encountered. Such light fixtures typically have a fixture housing which contains a light source therein, and a lens which mounts to the housing and permits the transmission of light therethrough. For such marine environments, it is preferred to include a sealing gasket between the lens and housing to prevent moisture from reaching the inside of the housing. 
   To join the lens to the housing, one type of known lens incorporates circumferential grooves therein which cooperate with leaf springs provided in the housing side wall which leaf springs resiliently engage the channels and releasably secure the lens to the fixture housing. Typically, such securement is accomplishment by inserting the lens into an initial position within the fixture housing and then rotating the lens into interlocked engagement with the leaf springs. 
   It is an object of the invention to provide an improved light fixture having an improved connector arrangement acting between the lens and fixture housing for releasably securing the lens thereto. 
   SUMMARY OF THE INVENTION 
   The invention relates to a light fixture including such an improved connector arrangement between a lens and fixture housing which permits engagement of the lens with the housing by initial insertion of the lens and subsequent rotation thereof to a locked position. 
   More particularly, the light fixture of the invention includes a can-like fixture housing having a peripheral rim at an open end thereof which rim projects radially outwardly and faces forwardly. The open end of the housing preferably defines a circular opening in which is received an annular mounting collar or skirt which projects rearwardly from the rear side of the lens and is adapted to fit within the circular open end of the housing in close relation therewith. The mounting collar or skirt includes circumferential locking channels which extend circumferentially and open sidewardly or radially towards the inside face of the housing fixture interior. 
   The improved light fixture further includes a plurality of plunger cartridges which each include a resiliently-biased, sidewardly-displaceable plunger disposed within a cartridge body. The plunger cartridges define an assembly comprising the cartridge body a plunger which extends sidewardly and a biasing member disposed in compression between the plunger and cartridge body which biases the plunger to an outwardly extended position but permits retraction of the plunger to an inwardly displaced position. Each plunger cartridge is individually mounted to the peripheral mounting rim of the fixture housing with the respective plunger thereof projecting through the housing side wall and extending into the open housing end for locking cooperation with the locking channels formed in the lens. 
   As will be discussed in further detail herein, these plunger cartridges and their cooperation with the fixture housing and associated lens defines an improved light construction providing an improved physical connection between the lens and housing and also providing an improved assembly process for this light fixture. 
   Other objects and purposes of the invention, and variations thereof, will be apparent upon reading the following specification and inspecting the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a plain view of a surface mount light fixture. 
       FIG. 2  is a side cross-sectional view of the light fixture as taken along line  2 - 2  of  FIG. 1 . 
       FIG. 3  is a side view of the light fixture. 
       FIG. 4  is a bottom view of the light fixture. 
       FIG. 5  is a side view of a second embodiment of the surface mount light fixture. 
       FIG. 6  is a bottom view thereof. 
       FIG. 7  is an enlarged side cross-sectional view of the light fixture of  FIG. 3 . 
       FIG. 8  is an enlarged cross-sectional view corresponding to  FIG. 2 . 
       FIG. 9  is a fragmentary cross-sectional view of the cartridge assembly mounted to the fixture housing and cooperating with the fixture lens. 
       FIG. 10  is a fragmentary cross-sectional view of a locking screw arrangement for the light fixture. 
       FIG. 11  is a perspective view of the fixture lens. 
       FIG. 12  is a side view thereof. 
       FIG. 13  is a bottom cross-sectional view thereof. 
       FIG. 14  is a plan view of a gasket. 
       FIG. 15  is a side cross-sectional view thereof as taken along line  15 - 15  of  FIG. 14 . 
       FIG. 16  is a perspective view of the fixture housing. 
       FIG. 17  is a side view of the fixture housing. 
       FIG. 18  is a perspective view of the cartridge body. 
       FIG. 19  is a plan view of the cartridge body. 
       FIG. 20  is a perspective view of a cartridge plunger. 
       FIG. 21  is a plan view thereof. 
   

   Certain terminology will be used in the following description for convenience and reference only, and will not be limiting. For example, the words “upwardly”, “downwardly”, “rightwardly” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the arrangement and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import. 
   DETAILED DESCRIPTION 
   Referring to  FIGS. 1 and 2 , the invention relates to a first embodiment of a light fixture  10  which is configured to be flush mounted to a desired environmental surface of a structure which may be a barrier or other static structure such as a wall or ceiling of a dwelling, motor home, or boat cabin. The light fixture  10  is particularly suited for environments in which moisture would be encountered such as in a marine environment. The light fixture  10  generally comprises a can-like fixture housing  11 , a light transmitting lens  12  and a ring-like mounting collar  14  which mounts to the fixture housing  11  and cooperates with housing  11  and the lens  12  to help secure the lens  12  to the fixture housing  11 . 
   Referring to  FIGS. 2 ,  16  and  17 , the fixture housing  11  comprises a circumferential side wall  15  which is enclosed on a bottom end by a semi-spherical bottom wall  16 . The opposite top end of the side wall  15  defines an open end  17  which is bounded by the interior side wall surface  18 . As such, the open end  17  preferably has a circular shape as viewed from above that is sized so as to receive the lens  12  at least partially therein as will be described in further detail hereinafter. At the upper terminal edge of the side wall  15 , an annular mounting flange  19  as provided which extends circumferentially around the periphery of the side wall  15  and projects radially outwardly therefrom so as to define a forward facing surface  20  that faces toward the lens  12 , and an opposite rearward facing back surface  21  which faces towards the mounting ring  14 . 
   As generally illustrated in  FIGS. 8 and 16 , the mounting flange  19  is stepped rearwardly in the middle thereof to define a shallow annular channel  22  which is defined radially outwardly of a flat land  23 . In the region of the annular channel  22 , the opposite sides of the rim  19  include respective pairs of connector tabs or fingers  25  which project rearwardly and are formed of the bendable material from which the flange  19  is formed. More particularly, the entire fixture housing  11  preferably is formed as a monolithic 1-piece structure of shaped metal, and preferably aluminum. In the region of the flange channel  22 , the flange material is partially cut and then bent rearwardly in cantilevered relation to define L-shaped connector tabs  25  and as such, the formation of the tabs  25  results in the corresponding formation of narrow slots  26  in the flange material. During initial formation of the tabs  25 , such tabs  25  typically are not yet bent into the L-shape generally seen in  FIG. 16 , which shape is subsequently formed by reforming of the tab  26  during assembly of the additional component parts as will be described in further detail herein. Additionally, a sideward opening, rectangular plunger window  27  is formed through the side wall  15  at a location generally centered between a respective pair of tabs  25 . 
   In addition to the tabs  25 , the annular flange channel  22  further includes at least two fastener bores  28  formed therethrough on diametrically opposite sides of the flange  19 . These fastener bores  28  are further illustrated in  FIG. 7  and are adapted to receive threaded fasteners  29  rearwardly therethrough for engagement or mounting of the light fixture  10  flush against the surface  30  of an environmental structure  31 . Preferably, the flange  19  has a depressed, counterbore like shape at the bores  28  to receive the heads of the fasteners  29  so as to lie substantially flush with the channel  22 . 
   Further as to the fixture housing  11 , this housing  11  as illustrated in  FIG. 17  also includes a locking bore  33  which projects sidewardly through the housing side wall  15 . 
   As to  FIGS. 2 ,  7 , and  8 , the fixture housing  11  is part of a housing assembly in that a light assembly  35  is mounted interiorly therein. This light assembly  35  has a support bracket  36  extending cross-wise and supported by the bottom housing wall  16 . The light assembly  35  further includes an aluminum reflector  37  which is supported by the bracket  36  and is aimed towards the open housing end  17 , and a light socket  38  in turn is supported within the reflector  37  and has a light bulb  39  electrically and mechanically connected thereto. The light socket  38  is supplied with electric power from electric wires  40  which are diagrammatically illustrated in  FIG. 8  and of any conventional structure. These electrical wires  40  exit the housing  15  through a rubber grommet  41  that is tight-fittingly mounted within a corresponding through passage  42  extending through the bottom housing wall  16 . This basic housing sub assembly of the housing  15  and the light assembly  35  is usable in multiple configurations as described hereinafter. 
   More particularly as to  FIGS. 3 and 4 , a first primary embodiment of the invention includes the mounting collar  14  which is disposed on the rearward, back side of the housing mounting flange  19 . The collar  14  preferably is formed of a plastic material having a suitable aesthetically pleasing color such as black since such collar  14  when mounted to the structure surface  20  ( FIG. 7 ) remains exposed during use so that said collar  14  has a dual function of forming part of the overall aesthetic appearance of the light fixture  10  and also serves a structural function for facilitating mounting of the light fixture  10  to the structure surface  30  and also for assisting in interconnecting and engaging the lens  12  so as to secure same on the housing  15 . 
   More particularly, the collar  14  preferably has a continuous circumferential outer surface  45  which faces radially outward and remains exposed when the fixture  10  is mounted in place. As seen in  FIG. 4 , the collar  14  in particular has a generally hollow construction defined by a circumferential outer wall  46  and a substantially continuous circumferential inner wall  47 . The outer wall  46  and inner wall  47  are radially spaced away from each other wherein the inner wall  47  lies closely adjacent to but is spaced slightly from the opposing outer face  48  of the housing side wall  15 . The outer and inner walls  46  and  47  are joined together radially by thin, radially extending webs  49 . The interconnected webs  49  and walls  46  and  47  are preferably formed together as a single unitary-piece of a suitable plastic material so as to be structurally rigid with open regions or pockets being formed circumferentially and radially between such web and wall structures. When assembled, the collar  14  lies closely against the back face  21  of the annular housing flange  19  as can be seen in  FIGS. 4 and 7 . 
   The collar  14  further includes cylindrical tubes  50  which define bores  51  that are positioned in registry or coaxially aligned with the corresponding fastener bores  28  formed in the flange  19 . As such, the fasteners  29  extend through both the fastener bores  28  and the aligned bores  51  so as to pass therethrough as seen in  FIG. 3  for engagement with the environmental structure  31 . In this manner, the light fixture  10  is mountable to the environmental structure  31  by the fasteners  29  with the collar  14  being sandwiched or disposed between the environmental surface  30  and the housing flange  19 . With the collar  14  positioned against the flange  19 , preferably an additional adhesive material such as a silicone adhesive is provided therebetween to not only provide fixed securement of the collar  14  to the flange  19 , but also to prevent the passage of water at the juncture between the collar  14  and flange  19 . 
   Referring to  FIGS. 4 ,  8  and  10 , the collar  14  also preferably includes an enlarged support block  52  extending radially between the outer and inner walls  46  and  47  in one quadrant thereof.  FIG. 4  illustrates a bottom view of this support block  52 , while  FIGS. 8 and 10  illustrate cross-sectional views thereof. As seen in  FIG. 10 , the support block  52  is formed substantially solid throughout except for the formation of a first bore portion  53  which extends horizontally, sidewardly therethrough and aligns with the locking bored  33  of the housing  15 . The outer portion of the support block  52  further includes an enlarged-diameter, second bore portion  54  wherein these bore portions  53  and  54  are adapted to threadedly receive a locking screw  55  therein as seen in  FIG. 10 . The locking screw  55  includes a threaded shank  56  that threadedly engages with the first bore portion  53 , and an enlarged head portion  57  which fits within the bore portion  54  and is rotatably driven by a suitable driving tool.  FIG. 10  illustrates the locking screw  55  in an extended, locked position with the inner end of the shank  56  being seated within a corresponding recessed portion of the lens  12  to prevent rotation of the lens  12 . A more detailed discussion of the locking cooperation between the screw  55  and lens  12  will be provided hereinafter. 
   Referring again to  FIG. 4 , the collar  14  also is provided with two mounting pockets  60  on diametrically opposite sides thereof which are each adapted to receive respective plunger cartridge assemblies  61  therein. Each pocket  60  is defined by a pair of pocket side walls  62 , which are circumferentially spaced apart, and is closed off by the outer wall  46  but has an open interior end  63  formed by a gap in the inner wall  47 . These cartridge assemblies  61  are mounted to the flange  19  and cooperate with the lens  12  to releasably engage the lens  12  to the housing  15 . As to the cartridge assembly  61 , each cartridge assembly  61  is adapted to be fixedly secured to the housing mounting flange  19  by the above-described tabs  25 . Referring more particularly to  FIGS. 4 ,  9  and  18 - 21 , the cartridge assembly comprises a cartridge body or housing  65  which is generally block-shaped and has a plunger chamber  66 , which opens upwardly and sidewardly from an open end  67 . As seen in  FIG. 18 , the outer bottom corners of the body  65  include rectangular securement notches  69 , wherein the body  65  is configured to be initially positioned beneath the mounting flange  19  in the position generally illustrated in  FIG. 9 , after which, the connector tabs  25  are then bent into the body notches  69  to trap and secure the cartridge assembly  61  to the bottom of the mounting flange  19 . In this position, the inner end of the body  65  lies closely adjacent to the housing wall  15  with the plunger chamber  66  being aligned sidewardly with the corresponding plunger window  27  formed in such side wall. 
   As seen in  FIG. 9 , the cartridge assembly  61  further includes a horizontally slideable plunger  70  which is resiliently biased by a biasing member  71 , preferably formed as a coil spring, which is disposed in compression between the end wall  72  of the plunger chamber  66  and the plunger  70  itself. More particularly, the chamber end wall  72  is formed with a sideward opening spring pocket  73  which receives the outer end of the spring  71  therein, and the bottom surface of the plunger chamber  66  also includes a shallow arcuate guide channel  74  ( FIGS. 18 and 19 ) along which the spring  71  extends. 
   As to the plunger  70 , such plunger  70  is illustrated in greater detail in  FIGS. 9 ,  20  and  21 . This plunger  70  has a generally U-shaped profile (when viewed from above) that is defined by parallel, spaced-apart plunger legs  76  which define a spring-receiving gap  77  therebetween. The legs  76  are joined together by a cam leg  79  that extends sidewardly thereacross and joins the legs  76  together into the rigid U-shaped profile. This cam leg  79  includes a projecting cam portion  80  that is defined by an inclined surface  81  wherein the cam portion  80  and associated cam surface  81  project through the plunger window  27  for engagement with the lens  12  as generally illustrated in  FIG. 9 . This plunger  70  is horizontally slideable within the plunger chamber  66  and therefore may be in the fully extended position illustrated in  FIGS. 9 ,  18 , and  19  or may be depressed inwardly against the spring  71  to at least a partially retracted position to permit removal of the lens  12 . 
   During assembly, the plunger  70  and spring  71  are initially assembled together and positioned within the plunger chamber  66  of the cartridge body  65  which cartridge assembly  61  is then positioned against the back surface  21  of the housing mounting flange  19  in the position generally illustrated in  FIGS. 8 and 9 . In this position, the cartridge body  65  is disposed, downwardly depending, circumferentially between a respective pair of the connector tabs  25  which tabs  25  are initially in their unbent, straight condition, and then once the cartridge assembly  61  is located therebetween, the ends of the tabs  25  are bent to the L-shaped profile referenced above. These connector tabs  25  hence are bent into the securement notches  69  to effectively grip and hold the cartridge assembly  61  in rigid engagement with the housing mounting flange  19 . Notably, the tabs  25  not only draw and restrain the cartridge assembly  61  against the back flange surface  21 , but they also locate the cartridge assembly  61  radially or sidewardly so as to lie closely against the side face of the housing side wall  15 . In this position, the plunger  70  projects through the respective window  27  and into the open end  17  of the housing  11  in a fully extended position which allows for free insertion of the lens  12  into such open end  17 . However, the plungers  70  as will be described hereinafter, also are at least partially retractable so as to permit rotation of the lens  12  to a locked position which locking lens rotation effects a partial retraction of the plunger  70  which plungers  70  then tight fittingly grip the lens  12  to hold same in a fully seated position within the housing  11 . Such engagement of the lens  12  with the plungers  70  will be described in further detail hereinafter. 
   It is noted that the cartridge assembly  61  is initially pre-mounted to the mounting flange  19 , and after which, the collar  14  is then mounted in place on the flange  19 . This is accomplished by aligning the cartridge pockets  60  of the collar  14  with the respective cartridge assemblies  61  and then as the collar  14  is moved against the flange face  21 , the pre-mounted cartridge assemblies  61  then fit into and align with said pockets  60 . As mentioned above, a suitable water resistant adhesive is provided between the collar  14  and flange  19  to fixedly secure same thereto. As seen in  FIG. 4 , the inner most end of the cartridge body  65  is able to be positioned within the respective opening  63  formed in the inner collar wall  47  so that the plunger  70  is able to pass through the plunger window  27 . 
   With this arrangement, the collar  14  thereby also serves as a spacer between the flange  19  and the environmental structure surface  31 , while the collar  14  also defines storage pockets  60  which hides the cartridge assemblies  61  that are notably positioned exteriorly of the environmental structure surface  31 . 
   The collar  14  also provides additional advantages as depicted in  FIGS. 5 and 6 . More particularly, an alternate collar  14 - 1  is illustrates which is formed so as to be readily interchanged with the above-described collar  14 . This collar  14 - 1  may have a different aesthetic appearance, and preferably, for example, is formed of a cast metal material having a desirable aesthetic finish applied to or formed on the exterior surface  45 - 1  thereof. It is understood, that the housing  11 , lens  12  and the additional components such as the fastener  29  and cartridge assemblies  61  are all formed identical to the above-described components and hence, the following discussion of collar  14 - 1  merely addresses the structural differences thereof as compared to the collar  14 . 
   More particularly as to  FIGS. 5 and 6 , the collar  14 - 1  preferably has a highly polished, metallic appearance thereto such as a corrosion resistant, chrome-like finish on surface  45 - 1  to provide a desirable aesthetic appearance. 
   As seen in  FIGS. 5 and 6 , the collar  14 - 1  includes an outer wall  46 - 1  that extends circumferentially and defines the outer surface  45 - 1 . It is noted that an inner wall such as wall  47  does not need to be provided in this rigid metal structure of the collar  14 - 1  and hence, while a support block  52 - 1  is provided for supporting the locking screw  55 , such support block  52 - 1  projects radially inwardly to a free end  85  thereof. Additionally, a pair of fastener supports  50  are provided which extend radially inwardly and define fastener bores  51 - 1  for the fasteners  29 . 
   Space circumferentially therefrom, additional pocket walls  62 - 1  are provided which project readily inwardly and define a pocket  60 - 1  that is configured to receive a respective cartridge assembly  61  in the same manner as previously described above. In particular, the cartridge assemblies  61  are pre-mounted by the connector tabs  25  to the mounting flange  19  and then the collar  14 - 1  is mounted to the flange  19  by a suitable water resistant adhesive. 
   Therefore, as can be seen, a common housing assembly is provided comprising the fixture housing  11 , light assembly  35 , and cartridge assemblies  61  which join together in combination with the demountable lens  12 . This basic combination may then be provided in combination with either of the collars  14  or  14 - 1 . 
   Turning first to the lens  12  as illustrated in  FIGS. 11-13 , the lens  12  generally comprises a main lens body  87  having a convex outer surface  88  which is exteriorly exposed during use and a flat planar surface  89  which faces rearwardly and extends about the outer peripheral lens edge  90 . 
   Also on the back side of the lens  12 , an annular, coaxial skirt  91  is provided which is defined by a continuous circular or circumferential inner surface  92  and a discontinuous, profiled outer surface  93  which includes various formations therein that allow for the connection of the lens  12  to the fixture housing  11  through cooperation with the cartridge assemblies  61  and in particular, through direct cooperation of the plungers  70  as well as the locking screw  55  with these formations in the lens skirt  91 . 
   More particularly, the skirt  91  is formed with a pair of L-shaped grooves  94  which extend circumferentially a partial distance about the circumference of the skirt  91  and are disposed on diametrically opposite sides thereof. The grooves  94  each include a rearward opening entry channel  95  which is adapted to align with the plungers  70  and permit the plungers  70  to be slid into the entry channels  95  with the plungers  70  in the extended position. The entry channels  95  further have forward ends which open into one end of a circumferential channel  96  that allows for the lens  12  to be rotated when seated in the open housing end  17  wherein the stationary plungers  70  essentially slide along the length of these circumferential channels  96 . 
   These channels  96  have a raised portion  97  in the middle thereof and a deeper recessed portion  98  at the blind end. Hence, during rotation of the lens  12 , the plungers  70  essentially travel along and are depressed outwardly as they reach the raised portion  97  by contact of the inclined surface  81  of the cam portions  80  which ride along the opposed groove surface, and the plungers  70  then are able to re-extend back into the recessed portions  98  which provides positive securement of the lens  12  in the fully rotated engagement position which position is defined by the point at which the plungers  70  fully seat within the recessed portions  98 . It is noted that  FIG. 13  diagrammatically illustrates the middle channel portion  97  as having a noticeably pronounced height relative to the portion  96  for illustrative purposes, with it being understood that such raised portion  97  may have a dimension which more closely approximates the entry channel  95  so long as the recessed portion  96  has a noticeable drop off to positively seat the plungers  70  therein. This seating of the plungers  70  and the recessed portions  96  does provide for positive locking of the lens  12 , although reverse rotation of the lens  12  is still permitted with sufficient reverse rotational force. 
   In view of the foregoing, to prevent inadvertent reverse rotation of the lens  12 , an additional locking recess  100  is provided in skirt  91 .  FIG. 12  illustrates one such recess  100  with it being understood that a second recess  100  is also located on the diametrically opposite side of the skirt  91  wherein only one recess  100  is engaged by screw  55  but both recesses  100  being provided so that the grooves  94  can be aligned with the plungers  70  in either orientation and the screw  55  will align one of the recesses  100 . Referring again to  FIG. 10 , one locking recess  100  ends up being aligned with the corresponding locking screw  55  when the lens  12  is in the final rotated position discussed above. As such, driving of the locking screw  55  to the fully seated position of  FIG. 10  places the free end of the screw  55  in the recess  100  and the cooperation of these two rigid structures prevents any reverse lens rotation. 
   In the foregoing manner, the lens  12  is positively seated in engagement with the fixture housing  11  and while locking is affected by the screw  55 , such screw  55  may also be disengaged to permit ready removal of the lens  12  where appropriate. 
   By the use of the individual plastic plungers  70 , such plungers  70  not only are readily mountable to the housing  11  through the use of the cartridge assembly  61 , but also are formed of a substantially rigid plastic material that provides improved positive locking between such plunger  70  and the lens  12  which is formed of rigid glass or other suitable translucent, rigid material like plastic. 
   Referring to  FIGS. 14 and 15 , the light fixture  10  of the invention also includes an annular elastomer gasket  102  which is compressed or sandwiched between the opposing lens face  89  and the housing mounting flange  19  as seen in  FIGS. 8-10 . This gasket  102  not only provides a water tight seal but also provides resistance to turning of the lens  12  to further assist in resisting reverse lens rotation. 
   With the foregoing arrangement, the same common component structures for the fixture housing  11  and lens  12  may be provided in multiple embodiments which provides an improved light construction that not only provides an improved connection between the lens  12  and housing  11  but also provides for ready adaptation of this housing/lens assembly in multiple configurations through the use of the collar constructions  14  and  14 - 1 . 
   Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.