Note: Descriptions are shown in the official language in which they were submitted.
CA 02551320 1998-O1-23
REMODELER LIGHT FIXTURE SUPPORT STRUCTURE AND METHOD
10
IS
BACKGROUND OF THE INVENTION
'The present invention relates in general to remodeler light fixtures or other
devices
20 installed in the walls andlor ceilings of buildings having support
structures and methods
of installing the support structures. More.particularly, it relates to simple
and reliable
remodeler light fixture support structures and methods of installing same in
azeas having
' limited, if any, access from above or behind the light fixture. Even more
particularly, it
relates to light fixture support structures that may be attached without tools
and which
25 meet Underwriters Laboratory (UL) standards and building codes.
Various methods, systems and apparatuses for installing lighting fixtures in
existing
construction as opposed to new construction have been developed and practiced
by the
lighting industry. Examples of prior systems and apparatuses for installing
lighting
30 fixtures in existing construction in the field of the present invention
include those
described in patents of the' assignee of the present application: U.S. Pat.
Nos. 5,031,084;
', 5,317,493; 5,222,800; 5,374,812; 5,452,816 and 4,646,212. Additionally,
U.S. Pat. No.
2,454,119 is related to the subject matter of the present application. These
patents are
representative of patents directed to the subject matter of tlae present
application.
The prior art constructions and methods all have disadvantages in that they
have a
plurality of parts requiring assembly to the structure often requiring the
installer to use
tools, including simple hand tools, during installation. Further, with the
prior art
constructions, installers are unable to separate the mechanical portion from
the electrical
portion of the installation, often requiring a qualified electrician to
perform the entire
installation rather than allowing a lesser skilled worker to install the
mechanical portion
and an electrician to install the electrical portion at a later time. These
prior remodelers
often comprise multiple unattached components and, thus, there is the
possibility that
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CA 02551320 1998-O1-23
unattached structural components might become separated from the fixture
during the
installation. When the unattached structural components fall during
installation in a
ceiling, the installer has to go down the ladder to retrieve the fallen
components. Thus,
the prior remodelers are more complicated than just a simple unitary part that
the installer
.5.. . ,, can hold in one hand while climbing a ladder. . .
These prior remodeler fixtures and methods are somewhat inadequate when used
in
"roughin" sections which allow contractors to do the mechanical and the
electrical work
required to finish the installation of a new light fixture in an existing
construction. In the
10' installation method typically used in remodeling applications, the trim
installation, or the
installation of the light fixture itself, is usually accomplished after
painting and other
mechanical alterations are made in the space. Tlie trim merely finishes the
installation of
the light fixture.
l5 Another unsolved problem experienced by the prior remodelers relates to the
uneven or
non homogeneous thiclmess of the planar surface surrounding the cutout where
the
lighting fixture was housed. Often the planar surface or the ceiling has
insufficient
Strength or structural integrity to support the light fixture without the
support structure
penetrating the ceiling or, in the worst case, cracking the ceiling. When this
occurs, the
20 ceiling is unable to properly support the lighting fixture. This is
especially true for
suspended ceiling tile, when, for example, the lighting fixture includes
integral electronic
or magnetic ballasting or transformers with the total weight being up to about
four or five
. pounds.
25 While suspended ceiling is not the typical remodeler installation, some
architects have
requested a remodeler light fixture product for use with suspended ceiling
tiles. Ideally,
the remodeler fixture would tie into the structural members or T bars that
support the tile.
' Some tiles for acoustic applications-can be about two inches thick and, as
such, have
structural integrity unto themselves. Yet, there is presently no known cost
effective
30 remodeler light fixture support structure available that could be safely
installed to meet
UL and code requirements and be sufficiently supported by suspended ceiling
tiles.
Another problem with prior round remodelers relates to rotation of the support
structure.
Prior round remodeler support structures are susceptible to rotating in the
planar surface
35 once human force is applied. If the support structure rotates in the planer
surface, such
rotation complicates the, installation and removal of protective and aesthetic
enclosures
typically used in food service areas and showers, etc.
Yet another problem with the prior remodelers relates to the need to
accurately and
40 securely position the junction box on the surface of the planar member
relative to the trim
positioned in the aperture. If the junction box is positioned too close to
.the trim or if the
junction box is left to be freely repositioned on the surface of the planar
member without
being located at a fixed distance fibm the trim, the junction box could become
repositioned to touch the trim causing the junction box to become overheated
and
45 , malfunction. Therefore, the junction box must be precisely positioned
relative to the trim
so that a thermal probe, for detecting properly placed insulation, is
installed at the
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CA 02551320 1998-O1-23
required height off the surface of the planar member or ceiling. More
importantly, the
junction box must be accurately and securely positioned on the surface of the
planar
. member relative to the trim positioned in the aperture at a location that
prevents the
junction box from overheating. Prior remodelers are not believed to have
reliable means
for repeatedly, consistently and predictably positioning the junction box.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved remodeler
Iight fixture
support structure for installation in planar members.
Another object of the present invention is to provide an improved system,
apparatus and
method for a remodeler light fixture support structure for installation in
planar members
that retains the light fixture support structure in position in the planar
surface by clamping
the planar surface between the lip portion of the perimeter member and a
retaining means.
Still another object of the present invention is to provide means for.
installing the
electrical and the mechanical elements of the rennodeler light fixture at
different times
and by installers having different levels of skill.
A further object of the present invention is to provide means for sandwiching
a planar
member of variable thickness without penetrating the surface of the planar
member.
Another object of the present invention is to provide improved methods,
systems and
apparatuses for securing the support structure to the surface of the planar
member.
Still another object of the present invention is to provide means for
consistently and
repeatedly positioning a junction box relative to the aperture.
A further object of the present invention is to provide means for marking the
position on
the planar surface where the aperture is to be cut to guide the installer in
cutting the
aperture in the planar member.
A still further object of the present invention is to provide a support
structure that can be
effectively installed in planar members made of relatively brittle material.
Another object of the present invention is to provide an improved system,
apparatus and
method for a remodeler light fixture support strucfire for installation in
planar members
that prevents the support structure from rotating in the aperture in the
planar surface when
rotational force is applied to the support structure.
In accordance with the present invention; one representative system for
supporting a light
fixture in an aperture formed in a planar member having a certain thickness
comprises: a
light f xture support structure including a perimeter member having a wall
portion and a
lip portion, the lip portion protruding outwardly from the wall portion; and
retaining
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CA 02551320 1998-O1-23
means, operatively connected to the perimeter member, fox retaining the light
fixture
support structure in position in the planar member by clamping the planar
member
between the lip portion of the perimeter member and the retaining means.
A tab or tongue, operatively connected to a junction box and operatively
connectable to
the support structure, is provided for accurately, repeatedly locating the
junction box
relative to the aperture and to facilitate compliance with UL requirements and
codes.
Moreover, in accordance with the methods, systems and apparatuses of the
present
invention, we have provided a mounting strap for securing a light fixture
support
structure to an aperture formed in a planar member, the mounting strap
comprising: an
elongated, planar member having a hook portion at one end and a v shaped two
leg
member at the other end.
I S In accordance with one aspect of the present invention, we have provided a
junction box
for use with a remodeler support structure installed in a plurality of
possible apertures
formed in existing construction, the junction box comprising: two side walls;
a top wall; a
front wall and a rear wall, the rear wall including means for housing a
thermal probe; and
a planar base plate having a top and a bottom surface and having a front
portion and a
rear portion, the planar base plate being operatively connected to the walls,
the front
portion extending beyond the front wall for a predetermined distance, the end
of the front
portion most remote fibm the front wall having at least two tips, one on each
side of the
end of the front portion, for interacting with the aperture such that the
junction box is
repeatedly and consistently positioned at the predetermined distance from any
one of a
plurality of apertures
In accordance with the present invention, one representative method for
installing a light
fixture in a planar member comprises the steps ofi cutting an aperture in the
planar
member having an inner and an outer surface at the point where the lighting
fixture is to
be installed; providing a light fixture support structure having a perimeter
and a lip
having an inner and an outer surface; providing at least two means,
operatively positioned
about the perimeter of the light fixture support structure, for retaining the
light fixture
support 'structure in position in the aperture formed in the planar member;
positioning the
light fixture support structure in the aperture; positioning the at least two
light fixture
support structure retaining means contiguous with the inner surface of the
planar
member; manipulating the ligk~t fixture support sfixcture_retaining means such
that the
light fixture support structure is maintained in position in the aperture by
clamping the
planar member between the lip of the light fixture support structure and the
retaining
means.
Other objectives and advantages of the present application will become
apparent from the
following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating a remodeler light fixture support
structure
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CA 02551320 1998-O1-23
according to the present invention;
FIG. 2 is a top view illustrating the perimeter member of the support
structure of FIG. 1;
, FIG. 3 is a sectional view of the perimeter member of FIG. 2 taken along
line 3--3;
FIG. 4 is an enlarged sectional view of a slot used to hold a retaining
mezxAber of the
perimeter member of FIG. 1;
FIG. 5 is an enlarged view of the portion of the perimeter member where a
spring
member for holding the trim is attached to the perimeter member;
FIG, b is a perspective view of a retaining member-according to the present
invention;
FIG. 7 is a view of the double winged end of the retaining member of FIG. 6
taken along
line 7--7;
FIG. 8 is a side view of the retaining member of FIG. 6;
FIG. 9 is a top view of the junction box and socket according to the present
invention;
FIG. 10 is a side view of the junction box of FIG. 9;
FIG. 11 is a plan view of a template usable with the present invention;
FIGS. 12 through 18 illustrate a sequence in a method according to the present
invention;
FIG. 12 illustrates the support structure of the present invention being
installed in a cut
hole or aperture in a planar member or ceiling;
FIG. 13 illustrates the installer moving the mounting strap 40 into contact
with the inner
surface of the, planar member to clamp the planar member (ceiling) between the
mounting
strap and the lip of the planar perimeter member of the support structure;
3S FIG. 14 illustrates the mounting strap of FIG. 13 after the installer has
properly
positioned the mounting strap;
FIG. I S illustrates the connection of the wiring to a junction box;
FIG. 16 illustrates the cflnnection of the junction box tab with the perimeter
member of
the support structure;
FIG. 17 illustrates the position of the junction box relative the planar
member (ceiling)
once connected to the perimeter member;
FIG. 18 illustrates the completed lighting fixture installed in the aperture
according to the
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CA 02551320 1998-O1-23
present invention; and
FIG. 19 is a partial perspective view of the sidewalls and the baseplate
assembly of the
junction box of FIGS. 9 and 10 according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In carrying out the present invention in preferred forms thereof, we have
provided
improved methods, systems and apparatuses for installing a light fixture in
existing
construction in a manner that significantly reduces installation time and
facilitates
flexible contractor scheduling in that the mechanical and the electrical
portions of the
installation can be readily accomplished at different times by different
personnel. The
methods, systems and apparatuses of the present invention are simple,
versatile, flexible,
low maintenance, cost effective, require no specialized tools and are space
efficient. The
methods, systems and apparatus of the present invention include unique
~mbinations of
elements and steps that_ facilitate the installation of a remodeler light
fixture by using a
support shveture having clamp means operatively connected thereto.
FIGS. 1-18 illustrate a representative new remodeler light fixture support
structure and
new methods of installing the remodeler light fixture in the support
structure. As shown
in FIGS. 1-8, the remodeler light fixture support structure 20 includes a
perimeter
member 22 having at least twa, and preferably three, slots 24, 26, 28
operatively formed
therein. The perimeter member can be circular or of any other geometric shape
which
corresponds to the shape of a desired light fixture. Specifically, the
perimeter member can
be shaped as desired, such as, for example, square, rectangular, elliptical,
pentagonal, etc.
As shown in FIGS. I-5, the perimeter member comprises a wall portion 30 and a
lip
portion 32 (the lip portion may be continuous or segmented) formed to protrude
outwardly from the wall portion 30 and, as illustrated, the perimeter member
is circular
and has the preferred three slots 24, 26, 28 formed therein spaced about one
hundred
twenty (120°) degrees apart. These slots 24, 26, 28 are for receiving a
light fixture
support structure retaining means or a mounting strap 40. The details 'of the
mounting
strap 40 will be described below. .
As shown in FIG..1, three representative trim springs 42, 44, 46 (three trim
springs are
presently preferred for the 1000 and 2000 series remodelers and four trim
springs
presently preferred for the 1100 series remodeler) are operatively positioned
about one
hundred twenty (120°) degrees apart around the interior periphery 48 of
the
perimeter member 22 for centering the trim or the lighting fixture once the
trim 50 (see
FIG. 18) is installed into the perimeter member 22. It should be understood
that more trim
springs or other supporting means could be used, such as, for example, four
(4) trim
springs positioned about ninety (90°) degrees apart (1100 series
remodeler). In
fact, any number of trim springs or other supporting means could be used as
long as they
support the trim 50 in accordance with known conventional standards.
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CA 02551320 1998-O1-23
The trim springs 42, 44, 46 are positioned on the inner periphery 48 of the
perimeter
member 22 such that the position of the trim springs 42, 44, 46 with respect
to the Prim 50
is constant regardless. of the planar member 52 thickness. In other words, the
distance
from the Iip portion 32 of the perimeter member 30 to the trim springs 42, 44;
46 is
constant. If this. distance were not constant, planar thickness would
determine trim spring
location. In that case, the thicker the planar material the farther away the
trim springs
would be located relative to the trim. If all trims were uniform along the
side or vertical
wails, fihis would not be a problem but the side walls of most trims are not
uniform and
actually curve inwardly thereby reducing the distance between the side walls.
As shown in FIGS. 3 and 4, because the mounting straps 40 interact with the
perimeter
member 22 in a specific matmer, the slots 24, 26, 28 are formed in perimeter
member 22
at the junction between the wall portion 30 of the perimeter member 22 and the
lip
portion 32. The wall portion 30 is; presently preferably, about 0.75 inch high
and has a tip
31 at one end which is, presently preferably, bent at about a fifteen
(lS°) degree
angle toward the interior portion of the perimeter member 22. The Iip portion
32 is
formed to protrude outwardly from the wall portion 30. The lip portion 32
extends .
outwardly from the wall portion 30 at about a ninety degree (90°) angle
therewith.
The slots 24, 26; 28 for receiving the mounting straps 40 are positioned in
the curved
portion of the perimeter member 22 between the lip portion 32 and the wall
portion 30
with the dimensions of the lip portion from the interior surface of the
perimeter member
22 toward the end of the lip portion most remote from the wall portion 30
being about,
prescntly preferred, 0.10 inch and the dimensions of the portion of the slot
24 from the
surface of the lip portion 32 most remote from the angled tip 31 of the
perimeter member
ZS 22 being about 0.15 inch toward the angled tip 31. The width of the slots
24, 26, 28 is,
presently preferred, about 0.41 inch.
As shown in FIG. 5, one additional slot 54 and related aperture 60 for
operatively
positioning the trim spxings 42, 44, 46 (see FIG. 1) are formed in the
perimeter member
22 with the circular aperture being located about 0.281 inch from the lower
surface of the
lip portion 32. The about 0.093 inch by about 0.510 inch slot 54 is positioned
about 0.220
inch above the center radius of the 0.136 radius aperture 60 toward the angled
tip 31, of
the wall portion 30 of the perimeter member 22.
It should be understood that all part dimensions are for illustrative purposes
and that
those skilled in the art could easily determine appropriate dimensions for a
plurality of
possible support structures to meet a plurality of different application
requirements.
As illustratcd in FIGS. 2 and 3, the perimeter member 22, is conventionally
formed from
about 0.032 inch thick C-1010 or C-1008 hot dipped galvanized G-60 minimum
spangle,
matte finish commercial quality metal. The perimeter member 22 can be either
formed as
a continuous member or formed by rolling such that there is an overlap
connecting
portion 36. The overlap 36 between ends of the perimeter member 22, is
presently
preferred, a minimum of about one (1) inch. The overlapping portion 36 is
operatively
connected in a conventional way such as, for example, by interlocking one
overlapping
thickness of the material into the other by a patented process known as "TOG-L-
LOK."
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Alternative connecting methods include, but are not limited to, welding,
riveting, using a
tab and slot connection, adhesive, nuts and blots, screws, etc. When using
three mounting
straps 40 and four trim springs, the minimt~rn angle between a mounting strap
slot and a
slot for the trim spring is presently preferably about thirty (30°)
degrees.
As shown in FIGS. 2 and 16, a single slot 70, relatively smaller than the
mounting strap
slots 24, 26, 28, is also operatively formed in the perimeter member 22. This
smaller slot
70 facilitates the accurate assembly of the support structure 20 at the
factory and is used
for securing a junction box 72 (as will be described later) in position
proximal an aperture
. 74 in a planar member 52. The position of the junction box 72 relative to
the aperture 74
must be accurate so that a thermal probe 76, for detecting properly placed
installation (not
shown), is automatically and repeatedly installed at the required height off
the ceiling or
planar member 52 (FIG. I2). The junction box 72 must be accurately and
securely
positioned on the surface 78 of the planar member 52 relative to the trim. 50
positioned in
the aperture 74 such that the junction box 72 is prevented from overheating.
In other
words, the junction box 72 must be reliably installed at a constant,
predictable distance
from the edge 80 of the aperture 74 in order to prevent junction box 72
malfunctions.
Thus, it is important to repeatedly, consistently and predictably position the
junction box
72 so that when tested, all requirements for Underwriters Laboratories (UL)
and building
codes are met.
An important component of the junction box 72 is a base plate 84 having a lip
86 for
positioning the junction box 72 relative to the aperture 74 in. the planar
member 52
regardless of the size of the standard light fixture aperture 74 that is cut.
The length of the
base plate 84 should be sufficiently long to properly position the thermal
probe 76
relative to the installed trim S0. A socket 88 is conventionally operatively
connected to
the junction box 72.
In an effort to assist the installer of the remodeler lighting fracture, the
installation system
includes a template 90 having the three standard sizes.for remodeler lighting
fixtures
depicted thereon. Specifically, as illustrated in FIG. 11, the template 90
includes, as a
minimum, indications for where the lighting fixture installer should cut the
planar
member 52 to install the remodeler lighting fixture. Specifically, size 2,000,
1,000 and
size 1,100 lighting fixtures having a radius of 17/8th inch, 29/l6th inches
and 33/8th
inches respectively are depicted on the template 90. The template 90 includes
detailed .
instructions for the installer concerning the size aperture 74 or hole to cut
in the planar
member 52 for each specific size lighting fncture_
As specifically shown in FIGS. 6-8, the mounting strap 40, as used in the
support
structure 20 and methods of the present invention, is, presently preferably, a
thin, long
flat member 94 having a hook portion 116 at one end and a v shaped two leg
member 96,
with each of the legs 106, 108 having a flange I02, 104 for engaging the
surface 78 of the
planar member 52 at the other end. The portion between the two legs 106, 108
and the
hook end 116 is, presently preferably, about three (3.0)inches long, about
0.018 inch
4~ thick and about 0.37 inch wide. In any event, the length of the flat member
94 should be
sufficient to cover any thickness of planar member 52 or ceiling likely to be
encountered.
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CA 02551320 1998-O1-23
As illustrated in FIG. 7, the two legs 106, 108 are positioned at about,
presently
preferably, sixty {60°} degrees with respect to each other. Connected
to each leg
106, 108 presently preferably, at about a ninety five (95°) degree
angle therewith
S are the flanges 102, 104, whicb. are aboutØi4 inch wide and about 0.625
inch long.
These flanges 102, 104 are the part of the mounting strap 40 which contact the
inner
surface 78 (see FIG. i 4) of the planar member 52 and distribute the weight of
the
remodeler light fixture such that the structural integrity of the material of
the planar
member 52 is not penetrated or broken down by the weight of the fixture. In
short, the
flanges 102, 104 distribute the weight of the light fixture over a larger
surface area of the
planar member 52 than those of the.prior art thereby avoiding complete
reliance on the
structural integrity of the planar material, such as, for example, how thick
or how thin the
planar member 52 is at any given point, for bearing the full weight of the
light fixture at
only a few sharp points of contact. The ninety five (95°) degree angle
between the
legs and the flanges provide a tighter, more secure installation.
Additionally, these flanges 102, 104 are the components which either dig into
the planar
member 52 or raise off the planar member 52 during attempted rotation of the
support
structure 20 when an installer attempts to rotate the support structure 20, as
will be
described below. It should be understood that dimensions of the flanges
102,104 can
vary and that the flanges illustrated were developed to meet a specific
physical test of
installation.
The angle of the connection between each leg 106, 108 and the long flat member
94
should be greater than about ninety (90°) degrees because of the
potential that the
mounting strap will slide away from the planar material when the mounting
strap is
pulled down into contact with the planar member. The angle of the connection
between
~ea.ch leg 106, 108 and the respective flange 102, 104 should preferably be
about ninety
(90°) degrees but less than about one hundred seventy {170°)
degrees
because the closer the angle between the leg and the flange is to one hundred
eighty
(180°) degrees, the smaller the surface area of the flange contacting
the planar
member for distributing the weight of the fixture.
The hook portion 116 of the mounting strap 40 is designed for holding the
mounting
straps 40 in a specific position in the perimeter member 22 after leaving the
factory and
before the support structure 20 is installed in an aperture 74 in a planar
member 52. As
illustrated in FIGS. 1 and 13, when the mounting straps.40 are initially
located in the slots
24, 26, 28 of the perimeter member 22, the inner surface 120 of the hook
portion 1 I6 is iu
contact with the inner surface 122 of the perimeter member 22 and the inner
surface 124
of the mounting strap flat member 94 is contiguous with the outer surface 128
of the
perimeter member 22 with the connecting portion 130 of the hook 116 being
pulled
contiguous with the portion of the mounting strap slots 24, 26, 28 placed
therebetween.
After assembling in this manner, the mounting straps 40 can be bent into
position and
nested in the center of the perimeter member 22. In this nested position, a
plurality of
light fixture support structures 20 can be efficiently packaged for shipment
and
distribution to end users.
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CA 02551320 1998-O1-23
One important element of the present invention is the light fixture support
structure
retaining means or mounting strap 40 which, when properly positioned in the,
at least two
and preferably three, slots 24, 26, 28 formed in the perimeter member 22 of
the support
~ structure 20, provides for the distribution of the weight of the installed
lighting fixture
such that the structural integrity of the planar member 52 is maintained. The
mounting
straps 40 include means for distributing the weight of the support structure
20 over a
larger surface area of the surface 78 of the planar member 52 than those of
the prior art
and, thus, allows the lighting fixture to be installed in planar members
having less than
optimal structural integrity such as, for example, ceiling tile_
. As shown in FIG. 8, in addition to distributing the weight of the lighting
fixture or trim
50 over the surface 78 of the planar member 52, the mounting strap 40 of the
present
invention is designed to prevent the support structure 20 from rotating in the
planar
.. member 52. Specifically, it is undesirable to have the support structure 20
rotate in the
aperture 74 in the planar member 52 when installing the trim or when
installing
incandescent light bulbs, etc. Ttcerefore, the surface 100 of the mounting
strap flange 102,
104 in contact with the planar member 52 "digs into° the surface 78 of
the planar member
52-that they contact whenever there is an attempt to rotate the support
structure 20
positioned inside the aperture 74 of the planar member 52. When attempting to
mtate the
support structure 20, one of the legs 106, 108 of at least one of the
preferably three
mounting straps 40 digs into the planar member 52. Specifically, the forward
leg in the
direction of iotation "digs in" while the rear leg is slightly raised into the
air above the
surface 78 of the planar member 52 during attempted rotation.
As shown in FIGS. 9, I0, 15-17 and 19, a unique junction box 72 and the
associated
socket 88, useful with the systems apparatus and methods of the present
invention
includes a base plate 84 having a tab or tongue 92 operatively connoted
thereto. The
base plate 84 has the tab or tongue 92 at one end 130 and the unique junction
box 72
including the thermal probe 76 at the other e>ud 110. The tab 92 is comtected
at the end
130 of the base plate 84 most remote from the junction box 72. At the end 130
most
remote from. the junction box 72, the base plate 84 has an arched poxtion 132
with,
presently preferred, two feet 140, 142, formed at the end thereof. The feet
140, 142 are
formed respectively at each end of the arched portion 132 and at about a
ninety degree
(90°~ angle with the plane of the base plate 84. The feet 140,,142 are
for
interacting with the aperture 74 formed in the planar~member 52 and
cooperaiing with the
base plate 84 and the tab 92 to insure that the junction box 72 .when
connected to the
support structure 20, perimeter member 22 and with the feet in the aperture
74, is
accurately positioned relative the aperture 74 such that all applicable
regulations and
codes are met {see FIGS. 16-18). The feet 140, 142 and the tab 92 combine to
prevent the
base plate 84 from changing locations/positions on the surface 78 of the
planar member
52 (ceiling) once installed, therefore insuring that the junction box 72
remains in the
installed position.
The new unique eight sided {including an access door or cover 146 when closed)
junction
box 72 is specially constructed with minimal gauge material. The junction box
has a
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CA 02551320 1998-O1-23
specifically designed access door 146 and a grounding wire 150 (see FIG. 19)
which is
uniquely attached to the box 72. An integral electrical cable clamp 152
operatively
positioned inside the junction box requires no tools for electrical capable
attachment
thereto while being able to pass requisite testing. Specifically, the internal
volume of the
junction box is about twenty-one (21) cubic inches. This internal volume is
believed to be
the optimum size for accommodating the number of electrical wires allowed to
be inside
a junction box of this type by code and regulation. The construction ofthe
unique
junction box includes opfiimization of the location of the thermal probe ?6
and the
incoming electrical wire and the strategic orientation of the flexible conduct
to minimize
the junction box's dimension so that the entire junction box can be installed
into a 33/4
inch diameter aperture. The complete junction box assembly is accomplished
without
hardware, such as, for example, screws, rivets or other hardware.
Specifically, as shown
in FIG. 19, a plurality of tabs 154 and a plurality of slots 156 slots (tab
and slot
construction) are utilized along with a snap and lock hinged door 146. The
junction box
72 provides optimal wiring and volume and is capable of being passed through a
33/4
inch diameter opening in~a building surface or planar member.
As shown, the junction box of the present application is constructed of a
minimal gauge
material. In particular, the eight sided junction box of the present
application is
configured such that the interior space is optimized for both interior volume
and for
installation through an aperture in a planar member approximately 33/4 inches
in
diameter, as mentioned above. The door 146 to the junction box is hinged at
158 and is
captive. The door when opened swings open and holds its open position without
fasteners
for easy access when connecting wiring within the junction box.
Another feature of the junction box concerns the connection of the ground wire
150 to the
junction box during the junction box assembly process by placing the ground
wire
between a tab 154 of the eight sided wall member and between a slot 156 in the
junction
box plate 84 so that the ground wire 150 is securely connected to the junction
box 72 (see
FIG. 19). Access for nonmetallic sheathed cable (Romex) is through the hinged
door
versus a knockout detail of the prior junction boxes. During the connection of
the cable,
the hinged knockout 160 remains intact versus the knockout slug of the prior
junction
boxes and does not require any tools in order to open whereas the prior art
required tools
to pry open the knockout.
Finally, the cable clamp 152 hinged to the wall of the junction box in
combination with
the access hole 160 size in the wall of the junction box provides for fast and
easy
insertion of the sheathed cable and automatically adjusts for 12-14 gauge NM
sheathed
cable. Further, the cable clamp 152 enables the junction box to resist UI,'s
50 1b. pull test
in one motion without having to use tools or having to perform a secondary
action to
clamp or fasten the sheathed cable. Specifically, the cable clamp is
structured such that
once the cable is inserted through a slot 162 in the clamp 152 aid an attempt
is made to
pull the cable back out of the junction box, the cable clamp 152 pivots about
the hinge
thereby compressing the cable between the opposing sides of the slot 162 in
the clamp
152 (strain relief feature).
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CA 02551320 1998-O1-23
When connecting wires} to the junction box, with the 1100 and 1000 series
remodelers,
the junction box can be hung temporarily from the perimeter member to assist
with the
wire connections. When connecting wires) to the junction box, an open hinged
knockout
160 is opened and a wire, preferably non-metallic sheathed cable, is pushed
through the
knockout opening 160 and through the cable clamp 152.
FIGS. 12-18 illustrate one method for installing a light fixture in existing
construction
using the illustrated circular light fixture support structure 20. First, an
aperture 74 is cut
in the planar member 52 at the desired location utilizing the template 90, as
described
above. Once the aperture 74 in the planar member 52 has been completed, the
assembled
support structure 20, including the preferred three mounting straps 40 and the
trim
springs 42, 44, 46, is inserted into 'the aperture 74. The light fixture
installer holds the
support structure 20 in position in the aperture 74, reaches in and pushes
down on the
mounting straps 40 (FIG. 13), preferably, one at a time until each mounting
strap 40
contacts the inner surface 78 of the planar member 52 such that the planar
member 52 is
sandwiched between the mounting straps 40 and the inner surface 34 of the lip
portion 32
of the perimeter member 22. As shown in FIG..14, once each riiounting strap 40
is in
contact with the inner surface 78 of the planar member 52, the light fixture
installer bends
the mounting straps 40 and secures the support structure 20 in position in the
aperture 74
effectively clamping the planar member 52 between the lip portion 32 of the
perimeter
member 22 and the retaining means or mounting strap 40.
At this point, it should be understood that, due to the flexibility of the
system and
methods of the present invention, it is possible to install the support
structure 20 either
before or after-the wiring has been installed. Specifically, as shown in FIG.
15,
conventional electrical wire 144 to be connected to the junction box 72. This
particular
connection, as mentioned above, could be accomplished by an electrician before
the light
fixtures support structure 20 is placed in the aperture 74 in the planar
member 52 or it
could be accomplished after the light fixtures support structure 20 is placed
in the
aperture, as will now be discussed.
Once the junction box 72 and the connected socket 88 are connected to the
electrical
wiring 144 and the support structure 20 has been installed in the aperture 74,
the junction
box tab or tongue 92 is inserted through the most narrow slot 70 in the
perimeter member
22 marked; "junction box", between the planar member 52 and the perimeter
member 22
and pulled into position such that the interior surface of each foot 140, 142
of the junction .
box base plate 84 is properly inserted into the aperture 74 contiguous with
the cut edge of
the planar member 52, as shown in FIGS. 16 and 17. Once the junction box 72 is
properly
positioned, the junction box tab 92 is inserted through the narrow slot 70 and
pulled down
until the junction box plate ~84 sits flat on the interior surface of the
planar member 52.
Then, the tab 92 is bent upward securing the junction box 72 into proper
position, as
shown in-FIG. 17.
As shown in FIG. 18, after the junction box 72 has been secured to the support
structure
20, thereby automatically repeatedly, consistently and predictably positioning
the
junction box 72 to meet Underwriters Laboratory and code requirements, the
socket 88 is
GI~RLF1CDA-DIV 12
CA 02551320 1998-O1-23
attached thereto, as is known in the art, and the trim 50 or the light fixture
is then
positioned inside the support structure 20. .
As mentioned in the background of the invention, no known previous remodeler
light
fixture support structures had~the capability of ready installation into
variable thickness
planar members and had the capability of being installed in planar members
having less
than ideal structural integrity or structural capability.
Thus, it can be sin that all objectives of the present invention have been
met.
Specifically, the present invention provides: an improved remodeler support
structure for
a light fixture installed in planar surfaces; an improved system and apparatus
wherein the
electrical and the mechanical elements are separated; means, operatively
positioned in the
support structure, for sandwiching a planar member of an infinite thickness;
means,
operatively positioned in the support structure, for securing the support
structure which
accepts finishing trim; improved methods, systems and apparatuses for
consistently and
repeatedly positioning a junction box relative to the aperture; improved
methods, systems
and apparatuses for securing the junction in place once acxurately located
relative to the
aperture and methods and apparatuses for marking the position in the planar
member
where the aperture is to be cut and guides the installer in cutting the
aperture.
Changes and modifications in the specifically described embodiments can be
carried out
without departing from the scope of the invention which is intended to be
limited only by
the scope of the appended claims.
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