Patent Publication Number: US-10317051-B2

Title: Light cove for perimeter of suspended ceiling

Description:
RELATED APPLICATIONS 
     This application is a United States national phase application of International Application No. PCT/US2016/036027 filed on Jun. 6, 2016, which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 62/171,423, filed on Jun. 5, 2015, the contents of which are incorporated in this application by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to a suspended ceiling system. More particularly, the invention relates to a lighting cove at the perimeter of a suspended ceiling system. 
     BACKGROUND 
     Some ceiling systems include a grid support system hung from an overhead structure (i.e., a suspended ceiling system) which includes an array of orthogonally intersecting longitudinal grid support members and lateral grid support members arranged in a fairly uniform pattern with regular intervals. The longitudinal grid support members and the lateral grid support members define a plurality of grid openings configured to support individual ceiling panels. Mechanical and electrical utilities (such as wiring, plumbing, etc.) may be conveniently routed in a hidden manner in the cavity or plenum formed above the grid support members and ceiling panels, making suspended ceiling systems a practical and popular ceiling option for residential, commercial, and industrial building spaces. 
     It is often desirable to create a cove along the perimeter of the suspended ceiling system (i.e., between the suspended ceiling system and an adjacent wall) into which a lighting module may be installed. Traditionally, this detail is completed with studs and drywall materials, and the architect details this part of the building with little planning or thought to how it gets constructed. As a result, ceiling light coves are often needlessly complex and difficult to construct, and therefore very expensive due to this added labor. Accordingly, there is a need for ceiling light coves which offer predictable lighting performance as well as simple and inexpensive installation. 
     SUMMARY 
     Embodiments of the invention include a lighting cove apparatus having a lighting cove including a horizontal arm, a first vertical leg attached to a first end of the horizontal arm, and a second vertical leg attached to a second end of the horizontal arm, wherein the first vertical leg and the second vertical leg each include a shoulder on an inside face; and a lighting module including a body and a plurality of retractable latches having downward facing points which retract into the body. When the lighting module is inserted into the lighting cove between the first vertical leg and the second vertical leg, the shoulders on the first vertical leg and the second vertical leg press on the retractable latches such that the retractable latches retract and the lighting module can pass the shoulders. When the lighting module passes the shoulders, the retractable latches re-extend and prevent the lighting module from being removed from the lighting cove. 
     Embodiments of the invention include another lighting cove apparatus having a lighting cove including a horizontal arm, a first vertical leg attached to a first end of the horizontal arm, and a second vertical leg attached to the horizontal arm, wherein the first vertical leg includes a downward facing hook and a lower protuberance on an outside face of the first vertical leg, the downward facing hook nearer the horizontal arm than the lower protuberance, the lower protuberance including a horizontal prong and a vertical prong; and a wall hook having a upper vertical portion, a lower vertical portion, and an upward facing hook which separates the upper vertical portion and the lower vertical portion. The downward facing hook on the outside face of the first vertical leg of the lighting cove rests on the upward facing hook of the wall hook, and the horizontal prong and the vertical prong are both in contact with an end of the lower vertical portion of the wall hook. 
     Embodiments of the invention include another lighting cove apparatus having a lighting cove, a wall hook, a lighting module, a hanging clip, and a hang wire. The lighting cove includes a horizontal arm, a first vertical leg attached to a first end of the horizontal arm; a second vertical leg attached to a second end of the horizontal arm; a wall attachment portion on an outside face of the first vertical leg having a downward facing hook and a lower protuberance; a first light attachment portion on an inside face of the first vertical leg having a shoulder; a second light attachment portion on an inside face of the second vertical leg having a shoulder; and a hanger attachment portion on an outside face of the second vertical leg having a downward facing hook and an upward facing hook. The downward facing hook of the wall attachment portion is nearer the horizontal arm than the lower protuberance, and the lower protuberance includes a horizontal prong and a vertical prong. The wall hook includes an upper vertical portion, a lower vertical portion, and an upward facing hook which separates the upper vertical portion and the lower vertical portion. The downward facing hook of the wall attachment portion of the lighting cove rests on the upward facing hook of the wall hook, and the horizontal prong and the vertical prong of the wall attachment portion of the lighting cove are both in contact with an end of the lower vertical portion of the wall hook. 
     The lighting module includes a body and a plurality of retractable latches having downward facing points which retract into the body. When the lighting module is inserted into the lighting cove between the first vertical leg and the second vertical leg, the shoulders on the first vertical leg and the second vertical leg press on the retractable latches such that the retractable latches retract and the lighting module can pass the shoulders. When the lighting module passes the shoulders the retractable latches re-extend and prevent the lighting module from being removed from the lighting cove. 
     The hanging clip includes a body and a protrusion attached to the body. The body of the hanging clip has a top edge contacting the downward facing hook of the hanger attachment portion of the lighting cove and a bottom edge contacting the upward facing hook of the hanger attachment portion of the lighting cove. The protrusion of the hanging clip has a hole. The hang wire has a first end inserted through the hole in the protrusion of the hanging clip and a second end secured to a structure 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       The invention is best understood from the following detailed description when read in connection with the accompanying drawing. It is emphasized that, according to common practice, the various features of the drawing are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawing are the following figures: 
         FIG. 1A  is a side view of a first lighting cove, according to an embodiment of the invention; 
         FIG. 1B  is a side view of a second lighting cove, according to an embodiment of the invention; 
         FIG. 2  is a side view of a wall hook, according to an embodiment of the invention; 
         FIG. 3  is a side view of a lighting module, according to an embodiment of the invention; 
         FIG. 4A  is a perspective view of a hold down clip, according to an embodiment of the invention; 
         FIG. 4B  is a side view of the hold down clip of  FIG. 4A , according to an embodiment of the invention; 
         FIG. 5A  is a perspective view of a hanging clip, according to an embodiment of the invention; 
         FIG. 5B  is a side view of the hanging clip of  FIG. 5A , according to an embodiment of the invention; 
         FIG. 6  is a side view of a wall hook mounted to a structural wall, according to an embodiment of the invention; 
         FIG. 7  is a side view of a lighting cove mounted to a wall hook, according to an embodiment of the invention, above the lighting cove; 
         FIG. 8  is a side view of hold down clips mounted to a lighting cove, according to an embodiment of the invention; 
         FIG. 9  is a side view of a hanging clip mounted to a lighting cove, according to an embodiment of the invention; 
         FIG. 10  is a side view of a lighting module mounted in a lighting cove, according to an embodiment of the invention; 
         FIG. 11  is a side view of a ceiling beam attached to a lighting cove, according to an embodiment of the invention; 
         FIG. 12  is a profile view of a connector clip, according to an embodiment of the invention; and 
         FIG. 13  is a profile view of an end cap attached to a lighting cove, according to an embodiment of the invention. 
     
    
    
     When referring to the drawing, like reference numbers refer to like elements throughout the various figures that comprise the drawing. 
     DETAILED DESCRIPTION 
     Embodiments of the invention provide for systems and components for securing a light fixture between a wall and a suspended ceiling in a lighting cove. Various terms relating to aspects of the invention are used throughout the specification and claims. Such terms are to be given their ordinary meaning in the art, unless otherwise indicated. Other specifically defined terms are to be construed in a manner consistent with the definition provided herein. As used herein, the singular forms “a,” “an,” and “the” include plural referents unless expressly stated otherwise. As used herein, terms such as “vertical,” “top,” “bottom,” “upward,” “downward” and the like refer to the orientation of the figures. The orientation of the figures is also typically the orientation in which the suspended ceiling is installed. Such directional terms are for illustrative purposes only and should not be interpreted as limiting the invention. Unless otherwise indicated, the various components of the system may be made of any suitable material, for example extruded aluminum. 
     Referring to  FIGS. 1A and 1B , exemplary lighting coves  100   a  ( FIG. 1A ) and  100   b  ( FIG. 1B ) are provided according to embodiments of the invention. Each lighting cove  100   a  and  100   b  includes a horizontal arm  102  and a first vertical leg  104  and a second vertical leg  106  attached to opposing ends of, and extending down from, the horizontal arm  102 . The first vertical leg  104  includes a wall attachment portion  110  on the outside face of the first vertical leg  104  (i.e., the side of the first vertical leg  104  facing away from the second vertical leg  106 ), and a first light attachment portion  120  on the inside face of the first vertical leg  104  (i.e., the side of the first vertical leg  104  facing toward the second vertical leg  106 ). The second vertical leg  106  includes a ceiling grid attachment portion  140  on the outside face of the second vertical leg  106  (i.e., the side of the second vertical leg  106  facing away from the first vertical leg  104 ), and a second light attachment portion  120   a  on the inside face of the second vertical leg  106  (i.e., the side of the second vertical leg  106  facing toward the first vertical leg  104 ). The second vertical leg  106  may also include a hanger attachment portion  130  on the outside face of the second vertical leg  106  above the ceiling grid attachment portion  140 . 
     The lighting coves  100   a  and  100   b  also include a plurality of screw holes  150  arranged around the lighting coves  100   a  and  100   b , for example at the intersection of the horizontal arm  102  and the first vertical leg  104 , at the intersection of the horizontal arm  102  and the second vertical leg  106 , and along the second vertical leg  106 . The lighting coves  100   a  and  100   b  differ in the length of the second vertical leg  106 . By including a longer second vertical leg  106 , the lighting cove  100   b  allows for the ceiling grid attachment portion  140  to be positioned lower with respect to the horizontal arm  102 . As a result, a deeper lighting cove  100   b  is created. In other words, a lighting module installed in the lighting cove  100   b  will be recessed farther above the suspended ceiling system than a lighting module installed in the lighting cove  100   a . Accordingly, the length of the second vertical leg  106  may be varied to achieve a desired cove depth. For the remainder of this description, embodiments will be described with reference to lighting cove  100   a , but it will be understood that the description applies equally to lighting cove  100   b.    
     The wall attachment portion  110  on the outside face of the first vertical leg  104  includes a downward facing hook  112  and a lower protuberance  114 . The downward facing hook  112  is nearer the horizontal arm  102  than the lower protuberance  114 . The lower protuberance  114  includes a horizontal prong  116  and a vertical prong  118  which extends toward the downward facing hook  112 . As explained in greater detail below, the wall attachment portion  110  enables the lighting cove  100   a  to be attached to a structural wall  10  ( FIG. 6 ) via a wall hook  200  ( FIG. 2 ). 
     The light attachment portions  120 ,  120   a  on the inside faces of the first vertical leg  104  and the second vertical leg  106  each include a downward facing hook  122 , an upward facing hook  124 , and a shoulder  126 . The downward facing hook  122  is nearest to the horizontal arm  102  and the shoulder  126  is farthest from the horizontal arm  102 . The upward facing hook  124  is between the downward facing hook  122  and the shoulder  126 . As explained in greater detail below, the light attachment portions  120 ,  120   a , optionally in conjunction with hold down clips  400  ( FIG. 4B ), enables a lighting module  300  ( FIG. 3 ) to be secured to the inside of the lighting cove  100   a.    
     The hanger attachment portion  130  on the outside face of the second vertical leg  106  includes a downward facing hook  132  and a upward facing hook  134 . The downward facing hook  132  is nearer the horizontal arm  102  than the upward facing hook  134 . As explained in greater detail below, the hanger attachment portion  130  enables a hanging clip  500  ( FIG. 5A ) to be attached to the second vertical leg  106  which attaches to a hanger wire  600  ( FIG. 9 ) to further support the lighting cove  100   a  from a structural support above the lighting cove  100   a.    
     The ceiling grid attachment portion  140  on the outside face of the second vertical leg  106  includes a downward facing hook  142 , an upward facing hook  144 , and a ledge  146 . The downward facing hook  142  is nearest to the horizontal arm  102  and the ledge  146  is farthest from the horizontal arm  102 . The upward facing hook  144  is between the downward facing hook  142  and the ledge  146 . As explained in greater detail below, the ceiling grid attachment portion  140  enables the lighting cove  100   a  to be attached to a ceiling beam  700  ( FIG. 11 ) via a connector clip  750  ( FIG. 12 ). 
     Referring to  FIG. 2 , a wall hook  200  is provided according to an embodiment of the invention. The wall hook  200  includes an upper vertical portion  210 , a lower vertical portion  220 , and a upward facing hook  230  which separates the upper vertical portion  210  and the lower vertical portion  220 . As mentioned above and explained in greater detail below, the wall hook  200  attaches the lighting cove  100   a  to a structural wall  10  ( FIG. 6 ). 
     Referring to  FIG. 3 , a lighting module  300  is provided according to an embodiment of the invention. The lighting module  300  includes a body  310  and retractable latches  320  on each side of the body  310 . Each retractable latch  320  includes a downward facing point  322  which, when retracted, does not extend beyond the body  310 . The retractable latches  320  are spring loaded so that a force is required to retract the retractable latches  320  into the body  310  and the retractable latches  320  extend back out once the force is removed. As mentioned above and explained in greater detail below, the lighting module  300  is secured inside the lighting cove  100   a  by the light attachment portions  120 ,  120   a.    
     Referring to  FIGS. 4A and 4B , a hold down clip  400  is provided according to an embodiment of the invention.  FIGS. 4A and 4B  are a perspective view and a side view, respectively, of the hold down clip  400 . The hold down clip  400  includes a vertical portion  410 , an upper angled portion  420 , a first bend  430 , a second bend  440 , a vertical prong  450 , and an angled prong  460 . The hold down clip  400  is made of a flexible but resilient material so that the hold down clip  400  is able to be bent by a force but also applies an elastic force in response. The upper angled portion  420  and the angled prong  460  are attached to opposite ends of the vertical portion  410 . The first bend  430  is attached to the upper angled portion  420  and bends back toward the vertical portion  410 . The second bend  440  is attached to the first bend  430  and bends back away from the vertical portion  410 . An end  442  of the second bend  440  should be approximately parallel to, and in line with, the vertical portion  410 . The vertical prong  450  extends from the vertical portion  410 . In the exemplary embodiment depicted in  FIG. 4A , the vertical prong  450  is a cut-out center portion of the vertical portion  410 . As mentioned above and explained in greater detail below, the hold down clip  400  helps secure the lighting module  300  inside the lighting cove  100   a.    
     Referring to  FIGS. 5A and 5B , a hanging clip  500  is provided according to an embodiment of the invention.  FIGS. 5A and 5B  are a perspective view and a side view, respectively, of the hanging clip  500 . The hanging clip  500  includes a body  510 , a top edge  512 , a bottom edge  514 , and a protrusion  520 . Two opposite corners  516  of the body  510  are rounded. The body  510  includes a hole  518  and the protrusion  520  includes a hole  522 . As mentioned above and explained in greater detail below, a hanger wire  600  ( FIG. 9 ) attaches to the hanging clip  500  to further support the lighting cove  100   a  from a structural support above the lighting cove  100   a.    
       FIGS. 6-12  demonstrate how the components described above are assembled to create a ceiling light cove as part of a suspended ceiling system. First, referring to  FIG. 6 , the wall hook  200  is attached to a structural wall  10  by one or more fasteners  12  (e.g., nails, screws, etc.) inserted through the upper vertical portion  210  of the wall hook  200  and into the structural wall  10 . Additional fasteners (not shown) may also be inserted through the lower vertical portion  220  for additional support, but may not be required. The wall hook  200  is attached to the structural wall  10  at a height above the desired height of the suspended ceiling. The exact height above the desired height of the suspended ceiling will depend on the length of the second vertical leg  106  of the lighting cove  100   a . A longer second vertical leg  106  requires the wall hook  200  to be attached to the structural wall  10  at a greater height above the desired height of the suspended ceiling. 
     Referring to  FIG. 7 , once the wall hook  200  is attached to the structural wall  10 , the lighting cove  100   a  is attached to the wall hook  200  by placing the downward facing hook  112  of the lighting cove  100   a  over the upward facing hook  230  of the wall hook  200  and then rotating the lighting cove  100   a  until the horizontal prong  116  of the lighting cove  100   a  contacts the structural wall  10 . Once in position, both the horizontal prong  116  and the vertical prong  118  are in contact with the lower vertical portion  220  of the wall hook  200 . The lower vertical portion  220  and the horizontal prong  116  prevent the lighting cove  100   a  from moving up, the downward facing hook  112  and the upward facing hook  230  prevent the lighting cove  100   a  from moving down or moving right (i.e., away from the structural wall  10 ), the lower vertical portion  220  and the vertical prong  118  prevent the lighting cove  100   a  from moving left (i.e., toward the structural wall  10 ). Therefore, the lighting cove  100   a  may be attached to the wall hook  200  without requiring the use of fasteners. As described in more detail below, the lighting cove  100   a  may be further secured in position by a hanger wire  600  ( FIG. 9 ) and by the suspended ceiling attached to the second vertical leg  106  of the lighting cove  100   a.    
     Referring to  FIG. 8 , hold down clips  400  are installed on each of the first vertical leg  104  and the second vertical leg  106  by inserting the end  442  of the second bend  440  into the downward facing hook  122  of each of the first vertical leg  104  and the second vertical leg  106 , pressing up to compress the first bend  430 , and inserting the vertical prong  450  into the upward facing hook  124 . Once the vertical prong  450  is inserted into the upward facing hook  124 , the hold down clip  400  may be released and the elastic force caused by the first bend  430  expanding will hold the hold down clip  400  in place. Each hold down clip  400  is installed with the angled prongs  460  pointing inward (i.e., toward the opposing first vertical leg  104  or the opposing second vertical leg  106 ). Although the hold down clips  400  are shown installed with the lighting cove  100   a  attached to the wall hook  200 , the hold down clips  400  may be installed at any time prior to the installation of the lighting module  300 , for example before or after the lighting cove  100   a  is attached to the wall hook  200  and before or after the hanging clip  500  is attached to the lighting cove  100   a . Typically, it will be easiest to install the hold down clips  400  prior to attaching the lighting cove  100   a  to the wall hook  200 . 
     Referring to  FIG. 9 , after the lighting cove  100   a  is attached to the wall hook  200 , the lighting cove  100   a  may be further secured by a hanger wire  600 . To install the hanger wire  600 , the hanging clip  500  is first attached to the lighting cove  100   a  by inserting the top edge  512  of the hanging clip  500  into the downward facing hook  132  of the lighting cove  100   a  and inserting the bottom edge  514  of the hanging clip  500  into the upward facing hook  134  of the lighting cove  100   a . The hanging clip  500  may be installed by first aligning the rounded corners  516  between the downward facing hook  132  and the upward facing hook  134 , and then rotating the hanging clip  500  into position. One end of the hanger wire  600  may then be inserted through the hole  522  in the protrusion  520  and tied, with the other end (not shown) of the hanger wire  600  secured to structure above the lighting cove  100   a.    
     Referring to  FIG. 10 , the lighting module  300  is installed into the lighting cove  100   a  by inserting the lighting module  300  into the lighting cove  100   a  with the downward facing points  322  of the retractable latches  320  facing away from the horizontal arm  102 . When the retractable latches  320  contact the shoulders  126  of the lighting cove  100   a , the retractable latches  320  will be pressed into the body  310  of the lighting module  300 , allowing the lighting module  300  to pass the shoulders  126 . Once the retractable latches  320  are past the shoulders  126 , the retractable latches  320  will extend and prevent the lighting module  300  from being removed from the lighting cove  100   a . Once installed, the lighting module  300  will contact the angled prongs  460  of the hold down clips  400 , which apply a downward force to the lighting module  300 . Accordingly, downward movement of the lighting module  300  is prevented by the shoulders  126  and the retractable latches  320 , and upward movement of the lighting module  300  is prevented by the hold down clips  400 , and the lighting module  300  is secured in place. 
     Although in  FIG. 8  the lighting module  300  is shown installed after the lighting cove  100   a  is attached to the wall hook  200  and the hanging clip  500  and the hanger wire  600  are installed, it will be understood that the lighting module  300  may be installed at any time during installation of the suspended ceiling. The lighting module  300  may also be removed by inserting a tool into the lighting cove  100   a  and applying pressure to the retractable latches  320  to cause the retractable latches  320  to retract back into the body  310 . The lighting module  300  may then be reinserted later, for example after cleaning, or replaced. Typically, the lighting module  300  will be installed after the lighting cove  100   a  is attached to the wall hook  200  and the hanging clip  500  is installed. It will further be understood that in some applications, the hanging clip  500 , the hold down clips  400 , or both may be omitted if the additional stability is not required. 
     Referring to  FIGS. 11-12 , a ceiling beam  700  may be attached to the lighting cove  100   a  using a connector clip  750 .  FIG. 11  is a side view of the ceiling beam  700  attached to the lighting cove  100   a .  FIG. 12  is a perspective view of only the connector clip  750 . The connector clip  750  includes a channel portion  760  and a beam portion  780  joined at a right angle to the channel portion  760 . The channel portion  760  is generally rectangular in cross section, includes two square corners  762  on diagonally opposing corners and two rounded corners  764  on the remaining two diagonally opposing corners, and has a substantially flat top surface  766  and a substantially flat bottom surface  768 . The beam portion  780  includes a plurality of holes  782 . 
     The connector clip  750  is attached to the lighting cove  100   a  by first vertically aligning the two rounded corners  764  between the downward facing hook  142  and the upward facing hook  144  of the lighting cove  100   a . The connector clip  750  is then rotated to vertically align the top surface  766  and the bottom surface  768  so that the top surface  766  and the bottom surface  768  engage with the upward facing hook  144  and the downward facing hook  142 . The ceiling beam  700  may then be secured to the connector clip  750 . The ceiling beam  700  includes, in cross section, a bulb  702  at the top, a vertical downward extending web  704 , and horizontally extending flanges  706  at the bottom of the web  704 . The ceiling beam  700  is attached to the connector clip  750  by securing one or more fastening elements, such as screws, though the holes  782  in the beam portion  780  of the connector clip  750  and into the web  704  of the ceiling beam  700 . In some embodiments, the flanges  706  of the ceiling beam  700  may rest on the ledge  146  of the lighting cove  100   a  for extra support. 
     After the ceiling beam  700  is installed, a ceiling panel  800  may be installed, for example by resting the ceiling panel  800  on the flanges  706  of the ceiling beam  700 . It will be understood that many variations on the design of the ceiling beam  700 , the connector clip  750 , and the ceiling panel  800  are possible. For example, rather than a ceiling panel  800  resting on the flanges  706  of the ceiling beam  700 , drywall may be attached to the bottom of the flanges  706 . Other ceiling panels  800  may slot over the flanges  706  instead of resting on the flanges  706 . It will further be understood that the ceiling beam  700  may be installed prior to the lighting module  300  being installed in the lighting cove  100   a.    
     Referring to  FIG. 13 , in embodiments where the lighting cove  100   a  does not extend fully to another wall, it may be desirable to enclose an end  160  of the lighting cove  100   a  with an end cap  900 . The end cap  900  includes a body portion  910  and a ledge portion  920  attached to the body portion  910  at a right angle. The body portion  910  includes a plurality of holes  912  which align with the screw holes  150  of the lighting cove  100   a . The end cap  900  is attached to the lighting cove  100   a  using a plurality of fasteners (e.g., screws) which are inserted through the plurality of holes  912  in the end cap  900  and the screw holes  150  of the lighting cove  100   a . Once attached, the ledge portion  920  is aligned with the ledge  146  of the lighting cove  100   a.    
     The invention is not limited to the embodiments described and exemplified above, but is capable of variation and modification within the scope of the appended claims.