Abstract:
A device for providing structural support comprising a longitudinal slot formed with inwardly projecting longitudinal flanges, and a support member extending outwardly opposite the longitudinal slot. Some embodiments may include a support member having a stop formed longitudinally along the edge of the support member. Other embodiments may include a plurality of longitudinal protuberances and/or detents. In addition, holes may be disposed in the support member and the support member may be formed with decorative elements to effectuate a particular design.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This patent application claims the benefit of U.S. Provisional Patent Application No. 61/229,463, entitled “Luminaire System and Method” filed Jul. 29, 2009 by the inventors George Mieling, Thomas Warton and Scott S. Yu, which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present invention relates generally to mechanical systems, and more particularly to an improved strut design for supporting a structure such as lighting systems and the like. 
         [0003]    Related art describes a wide variety of luminaires. Some of these relate to luminaire assemblies (U.S. Pat. No. 7,686,483), others relate to particular types of mounts (U.S. Pat. No. 7,686,470). The luminaire described by Bishop (U.S. Pat. No. 5,526,244) provides for a strut, but this strut does not provide for the modularity and ease of assembly of the present invention. A strut is described by Orlov (U.S. Pat. No. 6,517,222) provides support for a luminaire, but, again, does not provide for modularity and ease of assembly. 
         [0004]    What is needed is an improved strut that allows for modularity and ease of assembly, while providing additional strength and rigidity to the strut and any supported structure. 
       SUMMARY 
       [0005]    Disclosed herein is a device for providing structural support comprising a longitudinal slot formed with inwardly projecting longitudinal flanges, and a support member extending outwardly opposite the longitudinal slot. Some embodiments may include a support member having a stop or detent formed longitudinally along the edge of the support member. Other embodiments may include a plurality of longitudinal protuberances and/or detents. In addition, holes may be disposed in the support member and the support member may be formed with decorative elements to effectuate a particular design. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  illustrates an assembled luminaire system. 
           [0007]      FIG. 2  illustrates a coupling device for use in a luminaire system 
           [0008]      FIG. 3  illustrates a disassembled luminaire system. 
           [0009]      FIG. 4  shows different light rails that may be used with a luminaire system 
           [0010]      FIG. 5  illustrates an end view of certain embodiments of a strut. 
           [0011]      FIG. 6  illustrates embodiments of a strut. 
           [0012]      FIG. 7  illustrates differing views of certain embodiments. 
       
    
    
     DESCRIPTION 
       [0013]    Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. 
         [0014]      FIG. 1  illustrates fixture support system. In  FIG. 1 , a luminaire assembly  100  is depicted suspending from an overhead. The suspension assembly  110  includes both a structural cable, together with an electrical power cable  120 . It is connected to a chassis  114  which may provide an enclosure for an electrical ballast (not shown). One end of the chassis  114  is attached to a support arm  116 , and the chassis  114  may have an additional support arm  126 . The support arm  116  is slidably coupled to the chassis  114  such that the support arm  116  can be adjusted in relationship to the chassis  114 . Likewise a support arm  126  is slidably coupled to the chassis to allow it to move for better positioning. Depending on the length of the chassis  114  many other support arms can be added in series. The support arms are cross members in relation to the chassis  114 . Slidable coupling may be effectuated using set screws or other mechanisms to allow for sliding of the arms and then locking them in place once set. 
         [0015]    The chassis  114 , the support arm  116  and other parts of the fixture support system described below may be formed by available processes, including, but not limited to: extrusion, molding or machining. The material may be any suitable material providing sufficient strength and other properties, including but not limited to: aluminum, steel, ceramics or plastics. 
         [0016]    The support arms  116 ,  126 , (and others) are designed to hold in place light rails  118 . The light rails as shown in the  FIG. 1  include a reflector formed to direct light towards a particular direction and connectors such as sockets and plugs for connecting to a light source. The light source may be electrically coupled to a power source through the power cable  120 . The light rails  118  are connected to the support arms by hub assemblies  124 . The light rails  118  are designed to protect a lighting device and may include clear shields, baffles and other structures effectuating a similar result. The hub assembly  124  allows for rotation of the light rails  118 , thus allowing users to configure the direction of the light from the light rails  118 . The hub assemblies  124  also provide for coupling electrical power from the support arms to the light rail and its associated lighting device. 
         [0017]    The suspension assembly  110  is coupled to two suspension wires  112  which may be formed from a single wire, joined to the suspension assembly  110  thus having two separate tensions. A coupling device  122  provides for coupling the suspension wires  112  to the suspension assembly  110  and for the adjustment of the suspension wires  112 . The coupling device  122  secures suspension wires  112  to the suspension assembly  110  using a fastener such as a set screw (not shown). The coupling device  122  allows for height adjustment on the suspension assembly  110 , and a lateral adjustment on the suspension wires  112 . 
         [0018]    In the  FIG. 1  power to the luminaire is supplied along the suspension assembly  110  and to the power wire  120  into the chassis  114 . From the chassis  114  power can be applied to the light rails  118  in several different ways. Power can be routed through the arms  116  and  126  and associated hubs to reach each end of the light rail  118 . Or power could be routed through one of the arms  116  or  126  to reach a single end of the light rail  118 , having an additional power line run through the light rail to reach the other end of a lighting device located inside the light rail  118 . The lighting device may be either incandescent, fluorescent or LED Assembly and the like. 
         [0019]    In operation an assembler would suspend the fixture using the suspension assembly  110 . After the fixture is suspended, adjusting the coupling device  122  and the support arms  116  and  126 , to true the entire fixture. This allows for easy installation because variations in the installation can be easily rectified simply by adjusting the support arms  116  and  126  and the coupling device  122 . In addition, multiple fixtures such as the one shown in the  FIG. 1  may be suspended side-by-side. By adjusting the coupling device  122  and the support arms  116  and  126 , the fixtures can be trued to each other. 
       Coupling Device 
       [0020]      FIG. 2  shows a coupling device  200  for use in a luminaire system. The coupler  214  may be manufactured from any solid material capable of handling the stress depending on the application, preferably a metal such as steel or aluminum. The coupler  214  has a bore through one axis were a cable  210  is passed through the coupling device  200 . A set screw  218  (or similar fastener) is disposed through the coupler  214  to exert pressure on the cable  210  to lock the coupler  214  in place on the cable  210 . The coupler  214  must be capable of withstanding threading to allow the set screw  218  to function properly and secure the cable  210 . 
         [0021]    The coupler  214  has a second bore offset from the first bore for accommodating a cable  212 . The second cable is secured byte set screw  216 . In operation, the coupler  214  allows for relative positioning of two cables in close proximity and for easy adjustment and alignment of the two cables  210  and  212  in relation to each other. 
         [0022]    References in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure or characteristic, but every embodiment may not necessarily include the particular feature, structure or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Further, when a particular feature, structure or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one of ordinary skill in the art to affect such feature, structure or characteristic in connection with other embodiments whether or not explicitly described. Parts of the description are presented using terminology commonly employed by those of ordinary skill in the art to convey the substance of their work to others of ordinary skill in the art. 
         [0023]      FIG. 3A  illustrates a partially disassembled luminaire system. In the  FIG. 3A  a luminaire assembly  300  is depicted suspended from an overhead mount. The suspension assembly  310  may include both a structural cable and electrical power cable  320 . The suspension assembly  310  may also be formed from a solid material such as metal or plastic rod. The suspension assembly  310  is connected to a strut  324  which acts as a chassis for connecting to a ballast housing  314 . The ballast housing  314  need not contain a ballast. One end of the ballast housing is attached to a support arm  316 , and the ballast housing  314  may be connected to an additional support arm  326 . The support arm  316  is slidably coupled to the ballast housing  314  through the use a groove positioned on an end of the ballast housing  314  such that the support arm  316  is placed in the groove and can slide to different positions in the groove. The support arm  316  can be adjusted in relationship to the ballast housing  314 . Likewise a support arm  326  is slidably coupled to the ballast housing to allow it to move for better positioning. Depending on the length of the ballast housing  314  many other support arms can be added in series. Slidable coupling may be effectuated using set screws or other mechanisms to allow for sliding of the arms and then locking them in place once set in position. 
       Ballast In Arm 
       [0024]    One having skill in the art will appreciate that the ballast housing  314  may be alternatively designed to allow for more structural support. By locating a ballast into the support arm  316  or  326 , the ballast housing may need to be manufactured from material having different strength characteristics or shaped differently from that show in the  FIG. 3A . Relatively small ballasts are commercially available (B &amp; L Model NU6-1128-MSN/D for example) and support arms may be manufactured to completely house the ballast. A modified strut may be added to the ballast housing  314 , or if the ballast is located in a support arm or if a ballast is not needed, a modified strut may replace the ballast housing  314 . 
       Enhanced Strut 
       [0025]      FIG. 3B  shows a strut  324  that may be used to support ballast. This strut is held by the suspension assembly. The channel support  350  may be formed from conventionally available “strut channel” often used in construction. Added to the channel support  350  is a support member  352  extending along the length of the channel support  350 . The support member  352 , by increasing the moment of inertia, has the affect of strengthening the channel support  350  and reducing the deflection due to bending, torsional or twisting forces on the channel support  350 . This support member may be made of any solid material. In some embodiments the strut  324  is formed by extruding aluminum through a form. In addition, the strut  324  may be formed by bending sheet metal or through machining. The strut  324  may also be formed from non-metallic components such as plastics. For example, the strut  324  may be form by injection molding of plastics. 
         [0026]    Channel support  350  may be formed to any desired length, and the support member  352  may be welded on or otherwise affixed, or optionally extruded when formed. Also, the support member need not be continuous, but may be formed from several pieces positioned about the channel support  350  to achieve the desired result. Strut  324  is affixed to the ballast housing  314  or a ballast by an affixing means such as slide-on connectors, spring-loaded clamps, screws, clamps and any other affixing means that can provide a strong enough connection between the two to provide adequate physical support. The suspension assembly(s) are affixed to the strut via attachment points to the support member. In an alternative embodiment, the strut is attached directly to a surface such as a wall, ceiling or piece of furniture via attachment points to the support member. 
         [0027]    Referring to  FIG. 5A , the strut  324  is generally a U-shaped channel  350  having a support member  352  extending vertically from the top. A perspective view of this embodiment it shown in  FIG. 5B . The longitudinal sides  510  are turned inward forming a bottom side  520 . The opening between these upturned sides form a longitudinal slot. The edges of the bottom sides may be turned inward again so as to produce an inturned longitudinal flange  530 . The top portion of the support member  352  may be expanded to form a stop ( FIG. 6 ) that runs longitudinally along the length of the support member. This stop may have a rectilinear  610  or curvilinear  620  cross-section. One or more protuberances  630  or detents  640  may be located along the sides of support member  352  and run longitudinally along the length of the support member. The stops, protuberances and detents can be engaged by clamps or other elements and can be engaged by the suspension assembly. Holes  710  may be incorporated in the support member ( FIG. 7 ). These holes  710  can be engaged by clamps or other elements and can be engaged by the suspension assembly. These holes may be of a rectilinear or curvilinear cross-section. 
         [0028]    In addition the structural member  352  may be formed with decorative elements or the protuberances and detents may be formed to effectuate a decorative design. In a luminaire system, the shape of the structural member  352  may be effectuated in various ways to conform to the luminaire system. 
         [0029]    The support arms  316 ,  326 , (and others, not shown) are designed to hold in place light rails. The suspension assembly  310  is coupled to two smaller suspension wires  312  which may be a single wire. The wires  312  are fastened to the support arm  316 , but alternatively, the ends of the wires may be formed as a catch, with the affect of allowing the ends of the wires  312  to be disposed into a “key hole.” The key hole formed with a larger portion for accepting the catch and a smaller portion for holding the catch in place. A coupler  322  provides for the adjustment of the suspension wires  312  and secures them in place with a set screw (not shown). The coupler  322  allows for height adjustment on the suspension assembly  310 , and a lateral adjustment on the suspension wires  312 . 
         [0030]    Power to the luminaire is supplied along the suspension assembly  310  and to the power wire  320  then into the ballast housing  314 . From the ballast housing  314  power can be applied to the light rails in several different ways. Power can be routed through the arms  316  and  326  to reach each hub  124  which is at the end of the light rail  118 . Or power could be routed through one of the arms  316  or  326  to reach a single end of a light rail having an additional power line run through the light rail to reach the other end of a lighting device located inside the light rail if necessary. 
         [0031]    In operation, an assembler would suspend the luminaire using the suspension assembly  310 . After the luminaire is suspended, adjusting the coupler  322  and the support arm swing  316  and  326 , to true the entire assembly. This allows for easy installation because minor variations in the installation can be easily rectified simply by adjusting the support arms  316  and  326  and the coupler  312 . 
         [0032]      FIG. 4  shows an assortment of light rails  400  that may be used with a luminaire system. In the  FIG. 4  a baffle  410  provides for a covering over a light source that has the effect of allowing light out of the rail, but reducing glare when viewed from a side angle. The baffle  410  may be manufactured from semi-rigid material such that the baffle  410  snaps into the light rail and is thus held securely by compression. Alternatively, a baffle may be fastened in place by coupling it to the light rail using conventional fasteners such as screws and bolts. The baffle  410  as shown includes structure  414  to secure the baffle to an elongated lamp thus allowing the baffle  410  to hang suspended from the lamp. 
         [0033]    In a luminaire system different light rails may be employed by coupling them to a hub  412 , such that the hub provides mechanical support, pivotability and a means to provide the light source with electrical power. 
         [0034]    The above illustration provides many different embodiments or embodiments for implementing different features of the invention. Specific embodiments of components and processes are described to help clarify the invention. These are, of course, merely embodiments and are not intended to limit the invention from that described in the claims. 
         [0035]    Although the invention is illustrated and described herein as embodied in one or more specific examples, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention, as set forth in the following claims.