Patent Abstract:
An improved recessed lighting fixture allowing illumination from a lighting unit placed within a cavity of a planar surface, such as a ceiling or wall. The invention facilitates the ability to properly aim illumination because the user can aim the fixture while it is in place and illuminated. The invention is additionally designed to allow the substitution of lamps/light bulbs without requiring re-aiming of the fixture and to be used without modification with ceiling materials of varying thickness. The invention also includes an azimuthal adjustment mechanism wherein the lamp is mounted on a gimbal having a rack and pinion coupling to rotate the gimbal under control of a screw accessible from the exterior of the fixture and a horizontal aiming system.

Full Description:
This application is a continuation-in-part of a U.S. application filed on Feb. 28, 2002 and having Ser. No. 60/360,456. 

   BACKGROUND 
   1. Field of the Invention 
   The present invention relates generally to lighting fixtures and, more specifically, to an improved in-ceiling lighting fixture. 
   2. Prior Art 
   Recessed lighting fixtures are well known in prior art. However, such fixtures have been visually obtrusive in that all or some portion of the fixture falls below the ceiling line and disrupts the plane of the ceiling. Recently, low voltage halogen lights have become more popular because they are brighter and consume less energy. This has led to a need for further improvements in recessed lighting fixture design. 
   For aesthetic reasons, an in-ceiling light fixture is normally at least partially recessed into the planar surface of the ceiling. An opening is cut into the ceiling to illuminate the area beneath the light fixture. The fixture is generally mounted into the ceiling such that the bottom of the fixture (that part closest to the floor when installed) does not extend beyond the plane of the ceiling. Because the opening in the ceiling does not generally have a finished appearance, a trim or bezel is generally installed in the opening to enhance its appearance and conceal the cut out. Historically, the trim piece has been below the planar surface of the ceiling, visually diminishing the aesthetics of the ceiling. The same situation exists with wall mounted recessed lighting. 
   Another problem arising from the fixtures of prior art is that they could not accommodate differing thickness in ceiling materials. Ceiling panels are constructed in varying thicknesses and the trim/bezel must accommodate the multiple sizes of the ceiling material that are currently available in the market. Formerly, this required the manufacture and use of multiple sized trim kits and increased the costs of storage, materials and labor in installing recessed lighting. 
   Additionally, the light within the fixture must be properly aimed to achieve the desired design and aesthetic effect. In prior art fixtures, this is difficult and time-consuming. In prior art fixtures, aiming the light typically requires the user to first turn on the light to see where it is initially aimed, then turn off the light to let it cool down (as is required with halogen lighting), then adjust the aim of the light and then turn it on again to see where it is aimed after the adjustment. The process must be repeated until the light is aimed at the desired location. Thus, in the prior art, lights have been difficult to aim without generally requiring several iterations of aiming and adjusting the light, with a cool-down period between each of the several iterations. 
   Additionally, light bulbs of prior art fixtures have been difficult to replace without removing at least part of the fixture. Moreover, after such light bulb replacement, the aim of the light is often altered and requires re-adjustment and re-aiming. 
   Therefore, what is needed is an in-ceiling or recessed lighting fixture that is easy to install and use, permits ready adjustment of the aim of the light, and facilitates light bulb replacement without requiring re-aiming of the light. 
   BRIEF SUMMARY OF THE INVENTION 
   According to the present invention, an improved recessed lighting fixture allows aesthetically pleasing illumination when the fixture is placed within a cavity of a planar surface, such as a ceiling or wall. The fixture permits ready adjustment of the aim of the light by allowing the aim of the light to be adjusted while the fixture is in place and the light bulb is on. The aim of the light is controlled by two angles, namely, an azimuthal angle that lies in the horizontal plane and an elevational angle that lies in the vertical plane. The fixture also enables its light bulbs to be replaced without requiring re-aiming of the light. Additionally, the present invention may be used with ceiling materials of varying thickness without the need for a trim kit. 
   The basic elements of the fixture of the instant invention include: a housing designed to fit onto an inner surface of a ceiling or wall, a fixed mudding collar attached to the housing, an adjustable mudding ring that mates with the fixed mudding collar, and a trim unit mounted in the adjustable mudding ring. The trim unit comprises two versions, a round trim unit and a square trim unit, each of which comprises: means to retain the trim unit in the adjustable mudding ring, an elevational light aiming mechanism that controls the elevational angle of the light, a lamp support system attached to the elevational light aiming mechanism, and an opening through which light from the light bulb emanates and through which the elevational angle of the light can be adjusted with a screwdriver. 
   In the square trim unit, the azimuthal angle of the light is controlled by an azimuthal adjustment ring that resides in the square trim unit. In the round trim unit, the azimuthal angle of the light is controlled by a keyed azimuthal adjustment ring that resides in the housing. Both the square and round trim units have a setscrew that holds the adjustment ring in place after the adjustment ring has been rotated to the desired position. 
   Unlike prior art, the current invention contains means to adjust the elevational angle of the light while the light bulb is on, without the need to turn the light bulb off and to allow it to cool down. Additionally, the removability of the trim unit and the manner in which the trim unit is made removable allow rapid changing of the light bulb without altering the azimuthal or elevational angle settings of the light and without the need to disassemble the housing. 
   It is therefore an object of the invention to provide a lighting fixture designed to fit into a recessed space, such as in a ceiling. The light that emanates from the fixture must be strong enough to provide adequate illumination, but diffuse enough to prevent glare and avoid being harsh. Thus, the light must be aimable to allow for proper lighting for conditions within the area to be lit. As with any lighting fixture, light bulbs ultimately burn out and require replacement. In a recessed lighting fixture, replacing a burned out light bulb should not require readjusting the aim of the light. 
   It is a further object of the present invention to provide a recessed lighting fixture whose light can be easily aimed. 
   It is a further object of the present invention to incorporate a fixed mudding collar that mates with an adjustable mudding ring in such a way that the housing can be mounted onto surfaces having different thicknesses. 
   It is a further object of the present invention to provide a light fixture having a light that can be readily and repeatedly aimed with respect to azimuth and elevation. 
   It is a further object of the present invention to provide a method to quickly replace a light bulb without changing the aim of the light bulb. 
   Further features and advantages of the present invention will be appreciated by reviewing the following drawings and detailed description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a further understanding of the objects and advantages of the present invention, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numbers and wherein: 
       FIG. 1  is a perspective view of a square trim unit; 
       FIGS. 2A and 2B  are exploded perspective views showing the housing and fixed mudding collar in relation to the adjustable mudding ring and the trim unit; 
       FIG. 3  is a side view of the elevational light aiming mechanism; 
       FIG. 4A  is a top view of the lamp support system and elevational light aiming mechanism; 
       FIG. 4B  is a side view of the light bulb holder and elevational light aiming mechanism; 
       FIG. 5  is a top view of a square version of the trim unit; 
       FIGS. 6A and 6B  are, respectively, bottom and side views of a round adjustable mudding ring; 
       FIG. 7  is a bottom view of a square fixed mudding collar; 
       FIGS. 8A and 8B  are, respectively, top and side views of the keyed azimuthal adjustment ring; 
       FIG. 9  is a side view of a round trim unit; 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   In the following description, for the purposes of explanation, specific component arrangements and constructions and other details are set forth in order to provide a more thorough understanding of the present invention. It will be apparent to those skilled in the art that the present invention may be practiced without these specific details. In some instances, well-known manufacturing methods and structures have not been described in detail to avoid unnecessarily obscuring the present invention. 
   Referring first to  FIG. 1 , a perspective view of a square trim unit  10 A of the present invention is shown.  FIG. 2A  is an exploded perspective view of the fixture  91 A for a square trim unit  10 A showing its square fixed mudding collar  12 A, the adjustable square mudding ring  11 A, and the square trim unit  10 A. Contained within the square trim unit  10 A is a lamp support system  14  (FIG.  1 )that includes an azimuthal ring  60  ( FIGS. 1 and 5 ), an elevational light aiming mechanism  19  ( FIGS. 1 ,  3 , and  5 ) and a bulb mount  15 . 
   The housing  92 A,  92 B of the preferred embodiment is designed for installation in a cavity behind a planar surface, such as a wall or ceiling. Installation of the housing  92 A,  92 B requires an opening in the ceiling or wall on which the housing  92 A,  92 B will be mounted. The opening will initially have an unfinished appearance. The fixture  91 A,  91 B has a mounting surface  93  that rests flush upon the inner surface of the ceiling or wall on which the fixture  91 A,  91 B is being mounted. The fixed mudding collar  12 A,  12 B extends into the opening in the ceiling or wall so that the adjustable mudding ring  11 A,  11 B can be attached to it to provide a more finished appearance. The adjustable mudding ring  11 A,  11 B has steps  13 A,  13 B that mate with tabs  23 A,  23 B located on the fixed mudding collar  12 A,  12 B. The steps  13 A,  13 B and tabs  23 A,  23 B are configured so that by rotating the adjustable mudding ring  11 A,  11 B with respect to the fixed mudding collar  12 A,  12 B, the fixture  91 A,  91 B can be adjusted so that it fits surfaces of different thickness. 
   The adjustable mudding ring  11 A,  11 B also has a ring surface  17 , a mudding edge  21 , and a mudding line  22 . When the fixture  91 A,  91 B has been properly installed, the distance between the mounting surface  93  and the mudding line  22  is equal to or approximately equal to the thickness of the ceiling or wall on which the fixture  91 A,  91 B is being mounted. When the fixture  91 A,  91 B has been installed in this manner, the mudding edge  21 , the ring surface  17 , and the adjacent, unfinished edge of the ceiling or wall form a three-sided cavity that can be filled with mudding material and smoothed over so that none of the components of the fixture  91 A,  91 B extend beyond the ceiling or wall on which it is mounted. In this manner, once the adjustable mudding ring  11 A,  11 B has been adjusted to fit a particular ceiling or wall thickness, it is fixed in that position with mudding material. 
   The trim unit  10 A,  10 B is held in the adjustable mudding ring  11 A,  11 B by detents  9 A,  9 B that reside in the trim unit  10 A,  10 B and mate with the adjustable mudding ring  11 A,  11 B. This allows the trim unit  10 A,  10 B to be readily removed from, or installed in, the adjustable mudding ring  11 A,  11 B by simply using one&#39;s hand to pull the trim unit  10 A,  10 B out of the adjustable mudding ring  11 A,  11 B or push the trim unit  10 A,  10 B into the adjustable mudding ring  11 A,  11 B. 
   Referring to  FIGS. 3 , and  4 , detailed views of the elevational light aiming mechanism  19  are shown. This elevational light aiming mechanism  19  is the same regardless of whether it is used in the square trim unit  10 A or the round trim unit  10 B. The elevational angle of illumination is adjustable, even while the light bulb  20  is on and/or hot, by means of a unique rack and pinion assembly  28  and adjustment screw  36  ( FIG. 1 ) 
     FIG. 5  shows how the azimuthal aim of the light bulb  20  in the square trim unit  10 A can be adjusted through an arc of 0 to 90 degrees by rotating the circular track  60 .  FIGS. 8A ,  8 B, and  9  show the components that control the azimuthal aim of the light in the round trim unit  10 B. 
   The lamp support system  14  includes a bulb mount  15 , a bracket  32  a rack and pinion assembly  28 , and an adjustment screw  36  (best seen in  FIG. 1 ). The bulb mount  15  further comprises a banana slide rivet  43  and a banana/rack plate rivet  16 . The bracket  32  further comprises two rack plate rivets  44 A,  44 B, a banana slide opening  34 , a bracket base  33 , a bracket vertical surface  35 , and a rectangular opening  42  in the bracket vertical surface  35 . The rack and pinion assembly  28  further comprises a rack plate  27 , a rack plate lip  45 , an elongated bulb mount attachment hole  31  located in the rack plate  27 , a rectangular rack plate opening  41 , a rack  29 , and a pinion gear  30  The bulb mount  15  is attached to the bracket  32  via the banana slide rivet  43  and is further attached to both the bracket  32  and the rack and pinion assembly  28  via a single banana/rack plate rivet  16 . Accordingly, when the rack plate  27  moves translationally, the banana slide opening  34  forces the banana slide rivet  43  to move in an arc which, in turn, forces the bulb mount  15  to rotate about its banana/rack plate rivet  16 . The elongated nature of the bulb mount attachment hole  31  allows the banana/rack plate rivet  16  to move up or down as needed to accommodate the curvature of the banana slide opening  34 . In this manner, even while the light bulb  20  is on and hot, its elevational aim is adjustable via an adjustment screw  36  that turns the pinion gear  30  which causes the rack plate  27  to move translationally. Translational movement of the rack plate is obtained by controlling movement of the rack plate  27  via engagement of the rack plate lip  45  with the rectangular opening  42  and engagement of the rectangular rack plate opening  41  with the rack plate rivets  44 A,  44 B. 
   Referring next to  FIG. 5 , in addition to elevational aiming described above, the azimuthal angle of the light can be adjusted in the square trim unit  10 A. This azimuthal adjustment is made by removing the square trim unit  10 A from the adjustable mudding ring  11 A, loosening the setscrew  39 , rotating the azimuthal ring  60  to the desired setting, and then tightening the setscrew  39 . At this point, the square trim unit is ready to be re-installed in the adjustable mudding ring  11 A. The range of rotation of the azimuthal ring  60  is less than 360 degrees with respect to the square trim unit  10 A. However, this limitation is fully addressed by installing the square trim unit  10 A in any one of the four principal orientations available based on the four equal sides of a square. 
   In the round trim unit  10 B, the keyed azimuthal adjustment ring  76  controls the azimuthal angle of the light. The keyed azimuthal adjustment ring  76  resides in the housing  92 B and can be adjusted by rotating it by hand. To access the keyed azimuthal adjustment ring  76 , the round trim unit  10 B is removed from the adjustable mudding ring  11 B. The setscrew  39  in the keyed azimuthal adjustment ring  76  is then accessible, and can be loosened, by hand. After the setscrew  39  is loosened, the keyed azimuthal adjustment ring  76  can be rotated through 360 degrees while it resides in the housing  92 B. A straight edge  73  in the keyed azimuthal adjustment ring  76  acts as a key that allows the round trim unit  10 B to be inserted into the keyed azimuthal adjustment ring  76  in only one orientation, namely, in such a way that the bracket vertical surface  35  is aligned with the straight edge  73 . In any other orientation, the straight edge  73  would prevent the round trim unit  10 B from passing into the keyed azimuthal ring  76  because the bracket vertical surface  35  is relatively straight while the keyed azimuthal ring  76 , except for its straight edge  73 , is round. In this manner, the straight edge  73  allows the light bulb  20  to be aimed in only one azimuthal direction, namely, in the same azimuthal direction as the straight edge  73 . Once this direction has been selected by rotating the keyed azimuthal ring  76 , the setscrew  39  is then tightened and the round trim unit  10 B is re-installed in the adjustable mudding ring  11 B. 
     FIGS. 2A and 2B  show the steps  13 A,  13 B of the adjustable mudding ring  11 A,  11 B that make it adjustable with respect to, and when mated with, the tabs  23 A,  23 B of the fixed mudding collar  12 A,  12 B. The steps  13 A,  13 B in both the square and round version of the adjustable mudding ring  11 A,  11 B typically have four different heights, each one of which corresponds to one of four nominal thicknesses for ceiling or wall materials. Such nominal thicknesses are typically ½″, ⅝″, ¾″ or 1″. 
   The tabs  23 A on the square fixed mudding collar  12 A are spaced uniformly apart from one another along each side of the fixed mudding collar  12 A. However, among the four sides of the square fixed mudding collar  12 A, the tabs  23 A are spaced differently so that each set of tabs  23 A along any one of the four sides corresponds to one of four nominal ceiling or wall thicknesses in which the fixture  91 A may be mounted. This different spacing of the tabs  23 A among the four sides of the square fixed mudding collar  12 A is best seen in  FIG. 7 . The adjustable mudding ring  11 A is rotated to one of four positions so that its steps  13 A engage the tabs  23 A of the square fixed mudding collar  12 A. In this manner, the height of the steps  13 A allows the distance between the mounting surface  93  and the ring surface  17  to be adjusted to fit one of four nominal ceiling or wall thicknesses. Once the adjustable mudding ring  11 A has been installed on the fixed mudding collar  12 A, they can be secured to one another via screws inserted through screw holes  75 . After the fixed mudding collar  12 A and the adjustable mudding ring  11 A have been secured to one another, mudding material is applied to fill the cavity created by the mudding edge  21 , the ring surface  17 , and the opening in the ceiling or wall in which the fixture  91 A is being mounted. This provides a finished look to the installed fixture  91 A so that no portion of it extends beyond the outer surface of the ceiling or wall in which it is mounted. Once mudding material has been applied and installation is complete, only the trim unit  10 A can be readily installed and/or removed. 
   The tabs  23 B on the round mudding collar  12 B are typically spaced uniformly around the round mudding collar  12 B. The adjustable mudding ring  11 B is rotated to one of four positions so that its steps  13 B engage the tabs  23 B of the round fixed mudding collar  12 B. In this manner, the height of the steps  13 B allows the distance between the mounting surface  93  and the ring surface  17  to be adjusted to fit one of four nominal ceiling or wall thicknesses. Once the adjustable mudding ring  11 B has been installed on the round fixed mudding collar  12 B, they can be secured to one another via screws inserted through screw holes  75 . After the round fixed mudding collar  12 B and the adjustable mudding ring  11 B have been secured to one another, mudding material is applied to fill the cavity created by the mudding edge  21 , the ring surface  17 , and the opening in the ceiling or wall in which the fixture  91 B is being mounted. This provides a finished look to the installed fixture  91 B so that no portion of it extends beyond the outer surface of the ceiling or wall in which it is mounted. Once mudding material has been applied and installation is complete, only the trim unit  10 B can be readily installed and/or removed. 
   The description of the present invention has been made with respect to specific arrangements and constructions of a recessed, architectural lighting fixture. It will be apparent to those skilled in the art that the foregoing description is for illustrative purposes only, and that various changes and modifications can be made to the present invention without departing from the overall spirit and scope of the present invention. The full extent of the present invention is defined and limited only by the following claims.

Technology Classification (CPC): 5