Patent Abstract:
A recessed lighting fixture for a surface defined by a panel where the light is adapted for mounting behind the surface aligned with a panel opening having a selected configuration. The fixture includes a can having an opening on one side for escaping light, a mount for securing a light source in the can, and a flange member having a central opening matching the can opening. The can is mountable behind the surface with the can opening facing and selectively positioned in the panel opening and has a first mounting adapter about the can opening. A second mounting adapter is about the flange member opening. A plaster flange is secured to the flange member to define a substantially planar surface with an inner boundary matching the can opening and an outer boundary generally matching the panel opening. The first and second mounting adapters are adapted to selectively secure the flange member to the can with the plaster flange planar surface within the panel opening and substantially coplanar with the panel surface. A method of installing such a recessed lighting fixture is also provided.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION(S)  
       [0001]     Not applicable.  
       STATEMENT REGARDING  
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not applicable.  
       REFERENCE TO A MICROFICHE APPENDIX  
       [0003]     Not applicable.  
       TECHNICAL FIELD  
       [0004]     The present invention relates to recessed lighting, and more particularly to aesthetic mounting of recessed lighting.  
       BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIOR ART  
       [0005]     Recessed lighting is used in millions of homes, offices and other buildings throughout the United States and the world. Such lights used fixtures which are mounted behind a boundary of a room (typically above the ceiling), with an opening in the boundary allowing light to emanate from the light source in the fixture to the room.  
         [0006]     Recessed can lights are one type of recessed lighting which is widely used, both for area and spotlights. Can lights typically include a housing or can which is mounted around a socket for a suitable light bulb which is electrically wired to a light switch for turning the light off and on. Depending on the desired effect, the can may be reflective to maximize the amount of light emitted from the fixture. Such cans typically include a cylindrical opening, and are mounted to cross braces or studs behind the boundary (e.g., ceiling), with the cylindrical cans generally positioned behind a generally matching round opening in the room boundary. In new and/or retrofit installations, an installer may gain access behind the boundary through the opening for suitable mounting and wiring, after which the can may be inserted through the slightly larger boundary opening and suitably fixed to the mounting structure whereby its cylindrical opening is generally concentric with the round opening or hole in the boundary.  
         [0007]     Of course, it is as a practical matter virtually impossible to precisely align the can so that, when mounted, there is no space between the can and the boundary opening. This is true not only because it is difficult to precisely cut an exact round shape for the boundary opening, but also because precise lines are just generally difficult to cut in materials such as plasterboard or drywall which commonly are used to define the boundary. Moreover, not only are such cuts difficult, particularly when the craftsman has to reach up and make the cut overhead in a ceiling, but such materials are of a type which may have small pieces break off when making the cuts, leaving uneven edges.  
         [0008]     As a result, to provide an aesthetically pleasing fixture, ring shaped trim pieces have often been used, where the trim is secured to the lip of the can and extends outwardly to cover the unavoidable gap and provide a clean visible outer edge which is essentially perfectly circular. In some installations, however, the desired aesthetic design of the room is such that it is desired to have the recessed light appear integral with the boundary, without any such trim pieces. In those cases, the installer is required to plaster (commonly called spackle or “mud”) the gap between the light can and the boundary opening. However, it should be appreciated that such spackling is difficult to accomplish cleanly, given that it must go right up to the lip of the can, and moreover is highly susceptible to undesirably cracking or shrinking and leaving an unacceptable gap when the plaster dries.  
         [0009]     The present invention is directed toward overcoming one or more of the problems set forth above.  
       SUMMARY OF THE INVENTION  
       [0010]     In one aspect of the present invention, a recessed lighting fixture is provided for a surface defined by a panel where the light is adapted for mounting behind the surface aligned with a panel opening with a selected configuration. The fixture includes a can having an opening on one side for escaping light, a mount for securing a light source in the can, and a flange member having a central opening matching the can opening. The can is mountable behind the surface with the can opening facing and selectively positioned in the panel opening and has a first mounting adapter about the can opening, with a second mounting adapter about the flange member opening. A plaster flange is secured to the flange member to define a substantially planar surface with an inner boundary matching the can opening and an outer boundary generally matching the panel opening. The first and second mounting adapters are adapted to selectively secure the flange member to the can with the plaster flange planar surface within the panel opening and substantially coplanar with the panel surface.  
         [0011]     In one form of this aspect of the present invention, the panel and can openings are circular, and the can is selectively positioned with its opening concentric with the panel opening. In one further form, the first and second mounting adapters are mating screw threads. In another further form, the flange member includes a donut shaped screen adapted to support the plaster flange thereon. In still another further form, the screen is steel.  
         [0012]     In another form of this aspect of the present invention, a panel tape is secured to the plaster flange, and the tape extends beyond the plaster flange surface to overlap the panel about the outer boundary of the plaster flange surface when the flange member is selectively secured to the can.  
         [0013]     In another aspect of the present invention, a recessed lighting fixture is provided for a surface defined by a panel, where the light is adapted for mounting behind the surface aligned with a generally circular panel opening. The fixture includes a can having a substantially circular opening on one side for escaping light with a first mounting adapter about the can opening, a mount in the can for an electrical light, and a flange member having a central opening with a second mounting adapter about the opening. The can is mountable behind the surface with the can opening facing and substantially concentric with the panel opening. A ring shaped plaster flange is secured to the flange member, and defines a substantially planar donut shaped surface. The first and second mounting adapters are adapted to selectively secure the flange member to the can with the plaster flange donut shaped surface within the panel opening and substantially coplanar with the panel surface.  
         [0014]     In one form of this aspect of the present invention, the flange member central opening substantially matches the can around the can opening. In a further form, the plaster flange extends substantially completely to the flange member central opening.  
         [0015]     In another form of this aspect of the present invention, the mount is a light socket.  
         [0016]     In still another form of this aspect of the present invention, the first and second mounting adapters are mating screw threads.  
         [0017]     In yet another form of this aspect of the present invention, a donut shaped panel tape is secured to the plaster flange, with the tape extending beyond the plaster flange donut shaped surface to overlap the panel about the outer periphery of the plaster flange donut shaped surface when the flange member is selectively secured to the can.  
         [0018]     According to still another form of this aspect of the present invention, the flange member includes a donut shaped screen adapted to support the plaster flange thereon. In a further form, the screen is steel.  
         [0019]     In still another aspect of the present invention, a method of installing a recessed lighting fixture is provided, comprising the steps of (1) cutting a hole in a panel surface, the hole having a selected shape and size, (2) mounting a recessed light can behind the panel surface, the light can having an opening on one side for escaping light, (3) mounting a flange member with a ring shaped plaster flange to the can about the can opening, whereby the plaster flange defines a surface which is substantially coplanar with the panel surface and extends outwardly from the can opening to an outer boundary substantially matching the selected shape and slightly smaller than the selected size, and (4) spackling the joint between the panel surface and the plaster flange.  
         [0020]     In one form of this aspect of the present invention, the selected shape is circular.  
         [0021]     In another form of this aspect of the present invention, the hole in the panel surface and the light can opening are substantially concentric circles, and the flange member mounting step comprises threading the flange member onto the can.  
         [0022]     In still another form of this aspect of the present invention, a panel tape is secured to the plaster flange during the flange member mounting step, with a portion of the tape extending beyond the outer boundary of the plaster flange. In a further form, during the flange member mounting and the spackling steps, the portion of the tape extending beyond the outer periphery of the plaster flange is pressed against the panel surface surrounding the hole in the panel surface. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]      FIG. 1  is a side, partial cross-sectional view of a recessed light fixture in a ceiling according to the present invention;  
         [0024]      FIG. 2  is a side, partial cross-sectional view of a recessed light fixture in a ceiling according to another form of the present invention  FIG. 3  is a view from below of the  FIG. 1  embodiment, with the ceiling removed for illustration purposes and the underlying steel screen of the flange member partially visible (i.e., with the plaster portion not visible); and  
         [0025]      FIG. 4  is a bottom view similar to  FIG. 3 , showing the  FIG. 2  form of the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]     A first embodiment of the present invention is shown in  FIGS. 1 and 3 . As illustrated therein, the recessed light fixture  10  may is suitably supported between two studs or beams  14  beneath which is supported a suitable ceiling panel  18  made of, for example, drywall. While reference and description will be made herein to ceiling installations, it should be appreciated that the present invention may be advantageously used with essentially any space boundary, including not only ceilings, but also side walls.  
         [0027]     A housing  20  for the fixture  10  (as typically required by building codes) may be suitably mounted behind (above) the ceiling panel  18 . As illustrated, an opening  24  is cut through the panel  18 . In the illustrated embodiment, the opening  24  is generally cylindrical or circular, although it should be appreciated as described further below that it may be another selected shape. Access behind the ceiling panel  18  may be had through the opening  24 , for locating fixture components behind the panel  18  and for the installer to reach therein as necessary for installation.  
         [0028]     It should be understood that, for simplicity of illustration, the electrical wiring typically included with recessed light fixtures has been omitted from the figures.  
         [0029]     Mounting braces or brackets  28  may be suitably mounted between the beams  14  (e.g., by screwing bracket feet  30  thereto), and suitable connectors  32  may be provided for supporting the housing  20  on the brackets  28 . As illustrated, the feet  30  may be readily mounted to the beams  14 , even in retrofit applications. It should be understood, however, that still other mounting structures could be suitably used with the present invention. For example, in new construction, the brackets on either end may advantageously include a downwardly depending leg with a horizontal foot extending beneath the beam  14 , whereby the foot is secured to the bottom of the beam  14  (between the beam  14  and the ceiling panel  18 ).  
         [0030]     Suitably secured to the housing  20  is the recessed light can  40 . A desired light source, such as an incandescent light bulb, may be secured in the can  40  (e.g., in a suitable socket), with a cylindrical opening  44  for escaping light being at the bottom of the can  40 . It should be understood, however, that the present invention may be used with virtually any light source, including incandescent and Halogen lights, and area and spot lights, with the choice of light source being determined based on the desired lighting for the room.  
         [0031]     In accordance with the present invention, the outer surface of the can  40  includes a threaded portion  46 .  
         [0032]     Also in accordance with the present invention, a flange member  50  is provided, including a cylindrical central opening  52 , an annular flange  54  extending outwardly from the central opening  52 , and a suitable ring shaped plaster portion  56  suitably secured to the flange  54  and extending from an inner boundary abutting the central opening  52  to a cylindrical outer boundary  58  slightly smaller than the ceiling panel opening  24 .  
         [0033]     The cylindrical central opening  52  is threaded on its inner surface with threads which mate with the can threaded portion  46 , whereby the flange member  50  may be screwed onto the can  40 .  
         [0034]     The flange  54  may consist of a steel screen (see  FIG. 3 ), with the plaster portion  56  formed thereon. The texture and openings of the flange  54  may thus be sufficient to ensure that the plaster portion  56 , which may be formed wet thereon, will adequately secure thereto. Further, the flange  54  may also readily accept mounting screws  60  (see  FIG. 1 ) to further assist in ensuring the securement together of the plaster portion  56  and flange  54 .  
         [0035]     Moreover, it should be appreciated that the plaster portion  56  may be readily formed on the flange  54  prior to installation, with an smooth circular outer boundary matching the flange  54  shape. For example, a suitable cylindrical mold may be used to define such an outer boundary when the plaster forming the portion is placed on the flange  54 . Moreover, such manufacture may be more readily accomplished than if required to be done at the location of the light  10  (e.g., by placing the plaster on top of the upwardly facing flange  54  in a repetitive operation at a manufacturing facility, as opposed to having to reach up and place plaster on a downwardly facing ceiling surface). Also, whereas consistent clean lines around the can opening have heretofore further been particularly difficult to achieve due to the variously skilled large numbers of individual drywallers who have had to perform the task at each construction site, the present invention may much more readily allow for the manufacture of consistently clean lines. Still further, the present invention provides for reliable formation of the plaster portion  56  against the central opening  52 , without a crack developing as the plaster dries, and without portions of the plaster extending onto the clean and negatively impacting the aesthetic appearance of the installed light  10 .  
         [0036]     Instead, individual drywallers are required only to plaster (or spackle or “mud”) a joint of a type which they do all the time and are therefore reliably and suitably skilled to do so. Specifically, installation requires spackling over the annular seam between the ceiling opening  24  and the outer boundary of the plaster portion  56 .  
         [0037]     A suitable seam tape  64  such as is known for use in spackling drywall joints is provided on the plaster portion  56 . Rather than straight tape such as conventionally comes in rolls, the tape  64  may advantageously be in the shape of a ring with an inner portion  64   a  stuck to the plaster portion  56  and an outer portion  64   b  extending beyond the outer boundary  58  of the plaster portion  56 . As is known, tape of this type assists in ensuring that cracks do not develop in the spackle at the joint as the spackle dries.  
         [0038]     The tape  64  may advantageously be provided in the form of separate annular or donut shaped rings of a suitable size, with the tape  64  adhered immediately before threading together of the flange member  50  and can  40 , or the tape may be applied after threading of the flange member  50  to the can  40 . If necessary to protect the adhesive of the tape  64 , a suitable backing material may be provided, and/or multiple rings of tape  64  may be provided in a stack. However, it should be understood that any tape suitable for drywall joints may be advantageously used, including flat tape and mesh tape, and the tape may be provided on the joint in any suitable manner, including straight portions of tape applied at angles to one another to approximate the circular shape of the joint between the plaster portion  56  and the ceiling panel  18 .  
         [0039]     In the  FIGS. 1 and 3  embodiment, it should be appreciated that the can  40  should be secured so that the lip around its opening  44  is parallel to the bottom surface of the ceiling panel  18  and concentric with the circular opening  24  in the ceiling. The flange member  50  is then mounted onto the can  40  by turning the flange member  50  and screwing its threaded central opening  52  onto the can threaded portion  46 . The flange member  50  should be rotated to continue threading onto the can  40  until the bottom surface of the plaster portion  56  is substantially coplanar with the bottom surface of the ceiling panel  18 . At that position, the outer portion  64   b  of the tape  64  will overlap with and engage the ceiling panel  18 . Of course, the installer may press the tape against the ceiling to ensure good desired sticking. Thereafter, the installer may spackle the circular joint over the tape  64  in a manner which any reasonable competent drywaller can accomplish and frequently does, rather then being required to spackle the difficult area directly around the can opening  44 .  
         [0040]     A set screw  70  may be used to secure the flange member  50  and can  40  in that desired position.  
         [0041]      FIGS. 2 and 4  show a second embodiment of the present invention. This embodiment is similar in many respects to the  FIGS. 1 and 3  embodiment, and therefore the same reference numerals are used in illustrating this second embodiment, with similar but modified components having the same reference number plus prime (“′”). With this second embodiment, the flange member  50 ′ has a central opening  52 ′ threaded on the outside surface, with the can  40 ′ having its threaded portion  46 ′ on the inside.  
         [0042]     It should be understood, however, that still other embodiments may be used which incorporate the present invention. For example, while a circular/cylindrical shape may be advantageously used as described, particularly when the flange member  50  is rotated to advantageously position it on the can  40  by threading the two together, it would be within the scope of the present invention to secure the flange member  50  and can  40  together in other manners. For example, the two may be simply telescopically slid together and then suitably secured, as by set screws. In that case, since the flange member would not be rotated during installation, the flange member outer boundary  58  could essentially be any suitable shape which generally matches the shape, and is slightly smaller than, the opening in the ceiling (or wall), enabling it to be moved into the ceiling opening during installation to align its bottom surface and the ceiling bottom surface in the same plane.  
         [0043]     It should also be understood that the present invention eliminates the need to occasionally extend out the opening in the ceiling panel such as has occurred in the prior art, when the hole needed to be extended to the beams or studs to provide a base for securing a patch piece. With the present invention, the can  40  serves as a central base to which the flange member  50  may be secured, so that the ceiling opening  24  may be consistently located and sized at each light fixture  10  independent of the location of the beams or studs  14 .  
         [0044]     It should still further be understood that while reference is made herein to drywall and plaster, the present invention may also be advantageously used with different materials in which similar installation issues and limitations exist. For example, the present invention could also be used in connection with plaster walls which are not drywall panels such as often used in today&#39;s construction, or could be used in connection with still other ceiling and wall materials which would require that material seams or joints be hidden and which could more easily be hidden when the joint is formed between two adjacent flat surfaces. Therefore, “panel” has been used herein to broadly describe wall materials, though it should further be understood that such use is also not intended to be limited to any narrow or precise definition of that term.  
         [0045]     Moreover, it should also be understood that such joints may be advantageously hidden by use of materials which might not, in some definitions, strictly fit some narrow definition of “plaster” (i.e., a mixture of lime with sand or cement and water), and that the present invention contemplates the use of all such materials. As such, “plaster” as used herein is not intended to be limited to mixtures in which, for example, binding is accomplished by lime or fluidity is provided by water.  
         [0046]     Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained.

Technology Classification (CPC): 5