Note: Descriptions are shown in the official language in which they were submitted.
RECESSED LIGHTING ENCLOSURE AND INSULATION BARRIER
Field of the Inventive subject matter
100011 The field of the inventive subject matter is recessed lighting
enclosures.
Back2round
[0002] Weatherization and energy conservation have become a national priority
and the proper
insulation of attics, and consequently recessed light fixtures, is one of the
best ways of improving
heating and cooling efficiency and saving energy. Past and current solutions
for insulating light
fixtures address the barrier requirements around the fixture, but fail to
solve the problem of heat
loss above the fixture. Worse still, with the barrier and the insulation in
place around the fixture,
the heat source creates a chimney effect which draws air from the area below
and greatly reduces
the overall insulation efficiency.
[0003] Examples of previous solutions can be found in US 2,648,764 to Kirlin,
US 4,237,671 to
Munson, US 4,375,142 to McDonald, US 4,400,766 to Munson, US 4,754,377 to
Wenman, US
6,079,856 to Prestier, and US 6,286,980 to Meyer.
100041 Enclosures utilizing traditional vents and/or louver openings, such as
US 6,286,980,
address barrier functions, but fail to adequately address the balance between
energy efficient
insulation and dangerous entrapped heat buildup. Simply stated, insulation is
a heat and cold
trapping material and therefore a vent that is covered with insulation for the
purpose of insulating
is effectively blocked and creates a trapped heat buildup danger. To be
functioning vents and
avoid potentially hazardous heat levels, these openings must be uncovered
rather than blocked.
The trade off is a safer un-insulated energy wasting application or a
potentially dangerous
insulated one.
100051 Enclosures such as the use of clay flower pots placed over the light
fixtures are also
fraught with shortcomings and pose an extreme weight danger risk and the
potential of clay pots
falling through the ceiling, particularly in seismic areas. Pot shaped type
covers constructed of
mineral fiber or other fire resistant materials are lightweight, but also trap
potentially dangerous
levels of heat.
1
Date Recue/Date Received 2021-08-26
100061 Thus, there is still a need for a recessed lighting enclosure that
limits heat loss and cold
penetration through the ceiling, while allowing for managed air circulation to
guard against
hazardous levels of trapped heat buildup.
Summary of The Inventive subject matter
[0007] The inventive subject matter provides apparatus, systems and methods in
which a
housing has an open bottom, at least first and second side walls, and a
tapered roof In some
embodiments the housing additionally includes an opening in the roof
100081 In one aspect of some embodiments, the bottom is completely open,
although in less
preferred embodiments the bottom can be only partially open.
[0009] In another aspect of some embodiments, the housing is substantially
rectangular, or even
square in horizontal cross-section. Other shapes are contemplated, especially
those with
polygonal cross-sections, but a rectangular shape is currently thought to
provide the greatest
volume of air horizontally surrounding the lighting can. A square housing, for
example, is
thought to provide about 21% more air space horizontally about a lighting can
than a
corresponding cylindrically shaped housing. In most preferred embodiments, the
edges of the
housing are beveled. The sides can optionally have air holes.
100101 In yet other aspects of preferred embodiments, the roof is continuous
with each of the
side walls, and is folded to provide the eve(s) mentioned above. It is
contemplated that the roof
can have one or more openings, and more than one eve portion. The roof
opening(s) can
optionally be covered with a MylarTM or other flap, or a mesh (not shown).
Alternatively, the
roof openings could be sufficiently small that they need no covering at all to
prevent blown
insulation from entering the housing through the openings.
[0011] The housing can be made of any suitable material or materials,
including insulation.
In especially preferred embodiments, at least one of the walls has a cardboard
or other paper-
containing panel, which is internally lined with a sheet of insulation
material. Such sheets can
advantageously extend at least 0.4 inches (about 1 cm) farther down the first
side than the panel,
and can advantageously include a bottom cutout for wires to pass though the
wall.
2
Date Recue/Date Received 2021-08-26
100121 From a method perspective, a ceiling can be insulated by: providing a
housing having an
insulated first side, an open bottom, and a tapered roof; placing the housing
over the can such
that the first side is at least 2.5 inches, and more preferably at least 3
inches, from the can; and
ensuring that the roof has at least a first opening for egress of hot air.
100131 Preferred methods further include ensuring that the roof has an
overhang over the first
opening. During installation, all portions of the housing are preferably
distanced at least 3" from
the can, a bottom portion of at least the first side wall is folded back, and
where the ceiling can is
disposed near a joist, the folded back bottom portion to the joist using a
fastener. Tie strips are
also contemplated for holding the housing in place. Where the ceiling can is
powered by a wire
from outside the housing, it is contemplated to run the wire through a passage
in one of the side
walls, preferably near the bottom of the side.
[0014] One or more openings can be pre-punched, preformed or otherwise
disposed in the roof,
and in some embodiments it is contemplated that an installer would punch out
one or more such
openings.
[0015] The housing is preferably manufactured and shipped in a flattened
shipping
configuration, which is assembled into a roofed box configuration at an end-
user location.
Assembly can use chemical, mechanical, or any other suitable mechanical
connectors, as for
example magnetic. Once installed, mats, batts, blown or any other type of
insulation can be
disposed about housing.
[0016] In another aspect, there is provided a housing for a recessed light,
the housing
comprising: an open bottom when fully configured for use; at least first and
second side walls; at
least one of the side walls providing insulation with an R value of at least
0.1; a first opening; a
second opening; a tapered roof with a first eve portion overhanging the first
opening and a
second eve portion overhanging the second opening, wherein an upper portion of
the recessed
light is below the first opening and the second opening.
100171 In another aspect there is provided a method of insulating a ceiling
can of a recessed
light, comprising: providing a housing having an insulated first side wall, an
open bottom, and a
tapered roof; placing the housing over the can such that the first side wall
is at least 3" from the
3
Date Recue/Date Received 2021-08-26
can; ensuring that the roof has a first opening for egress of hot air;
ensuring that the roof has a
first eve portion overhanging the first opening; ensuring that the roof has a
second opening for
egress of hot air, ensuring that the roof has a second eve portion overhanging
the second
opening; and ensuring that an upper portion of the recessed light is below the
first opening and
the second opening.
100181 In another aspect, there is provided a housing for a recessed light
comprising: an open
bottom when fully configured for use; at least first and second side walls,
the first side wall
having a fold line along a vertical axis; at least one of the side walls
providing insulation with an
R value of at least 0.1; and a tapered roof, wherein an upper portion of the
recessed light is below
a lower edge of the tapered roof
[0019] In general, the inventive subject matter is contemplated to provide a
much-needed
improvement for insulating around and above potential fire hazard heat
sources. Without
wishing to be limited to any particular theory or mechanism of action, it is
contemplated that
embodiments claimed herein utilize compartmentalization and the principle of
hot air rises and
cold air falls, to better direct, restrict, manage, and control (hot/cold)
airflow and desired
temperature. Preferred embodiments are thought to restrict cold air
penetration, while providing
means for dangerous heat source elevated temperatures to diffuse and/or
escape. In the roof, one
or more converging diagonal panels are thought to reduce the upper internal
area, thus reducing
the external exposure area.
[0020] Various objects, features, aspects and advantages of the inventive
subject matter will
become more apparent from the following detailed description of preferred
embodiments, along
with the accompanying drawing figures in which like numerals represent like
components.
Brief Description of The Drawing
[0021] Figure 1 is a perspective view of an assembled housing.
[0022] Figure 2 is a perspective view of the housing of Figure 1, depicted in
a flattened shipping
configuration.
4
Date Recue/Date Received 2021-08-26
100231 Figure 3 is a perspective view of an alternative housing in which the
roof has two vertical
portions and two sloped portions.
[0024] Figure 4 is a plan view of an opened, unassembled cross section of the
housing of
Figure 3.
100251 Figure 5 is a perspective view of a partial assembly of the housing of
Figure 3.
100261 Figure 6 is a vertical cross section of the housing of Figure 3, with
optional baffle, as
installed about a can light fixture and its associated electrical box and
wiring.
[0027] Figure 7 is a vertical cross section of the housing of Figure 3,
showing contemplated air
flow.
100281 Figure 8 is a perspective view of an alternative housing.
[0029] Figure 9A is a cut-away cross sectional views of a roof panel of the
housing of Figure 8,
showing a diagonal deflection integral "baffle' opening.
100301 Figure 9B is a cut-away cross sectional view of the roof panel of
Figure 9A, in which the
baffle opening is pushed more horizontally, and thereby allows more hot air to
escape.
[0031] Figure 9C is a cut-away cross sectional view of the roof panel of
Figures 9A and 9B, but
here showing an overlying flap.
100321 Figure 10 is a plan view of a cutout sheet of material that forms the
walls and roof of the
housing of Figure 8.
[0033] Figure 11 is a plan view of a large sheet of material that could be cut
to produce multiple
copies of the cutout sheet of Figure 10.
100341 Figure 12 is a plan view of a die cut sheet of material that forms a
panel, which can be
folded and fastened to a similar sheet to form the housing of Figure 13.
[0035] Figure 13 is a perspective view of an assembled housing using two
panels of Figure 12.
Date Recue/Date Received 2021-08-26
100361 Figure 14 is perspective view of yet another alternative housing,
showing positioning of a
housed lighting with a space created by the housing and the ceiling.
[0037] Figure 15 is a side view of mating ratchet rivet parts.
[0038] Figure 16 is a side view of Christmas tree type fastener parts
100391 Figure 17 is a side view of an arrow type fastener.
100401 Figures 18a and 18b show a side view of the beveled edge 320 of housing
300 in Figure
13.
[0041] Figure 19 illustrates an embodiment of the inventive subject matter in
the assembled
configuration.
100421 Figure 20 illustrates an embodiment of the inventive subject matter in
a partially folded
configuration.
[0043] Figure 21a and 21b illustrate an embodiment of the inventive subject
matter being
reconfigured from a partially folded to open configuration ready for use.
100441 Figure 22 illustrates an embodiment of the inventive subject matter in
a partially unfolded
configuration.
[0045] Figure 23a and 23b illustrates an embodiment of the inventive subject
matter in a flat,
folded conformation ready for shipping and/or storage.
100461 Figure 24a and 24b show views of production panels laid flat after
manufacture and prior
to folding for storage, shipping or use.
[0047] Figure 25 illustrates a flat view of an embodiment of the inventive
subject matter as it
would be manufactured, prior to folding and final assembly.
100481 Figure 26 illustrates a perspective view of an embodiment of the
inventive subject matter
partially folded with the top panels not yet secured to each other.
6
Date Recue/Date Received 2021-08-26
100491 Figure 27 illustrates an assembled embodiment of the inventive subject
matter. In this
illustration the inventive subject matter does not include a vent.
[0050] Figure 28 illustrates an embodiment of the inventive subject matter
where the top panels
converge to form a flat rather than pointed top.
100511 Figure 29 illustrates an embodiment of the inventive subject matter
that is partially
collapsed in preparation for shipping and/or storage.
[0052] Figure 30 illustrates an embodiment of the inventive subject matter and
depicts
exemplary folding lines that have been scored to allow for partial separation
of membrane and
glass panel.
100531 Figure 31 illustrates an embodiment of the inventive subject matter
where an internal cut
runs partway to the edge to mitigate separation of the panel and membrane.
[0054] Figure 32 illustrates an improved roller for use in the manufacture of
embodiments of the
inventive subject matter.
100551 Figure 33 illustrates a roller machine for use in the manufacture of
embodiments of the
inventive subject matter.
Detailed Description
100561 The following discussion provides example embodiments of the inventive
subject matter.
Although each embodiment represents a single combination of inventive
elements, the inventive
subject matter is considered to include all possible combinations of the
disclosed elements. Thus
if one embodiment comprises elements A, B, and C, and a second embodiment
comprises
elements B and D, then the inventive subject matter is also considered to
include other remaining
combinations of A, B, C, or D, even if not explicitly disclosed.
[0057] Figure 1 shows an assembled housing 10 that provides an optional baffle
to restrict and
direct airflow, and a partially covered (enclosed) area with exposure to
external air for the
purpose of obtaining a controllable internal air temperature. Figure 2 shows
the same enclosure
in a shipping configuration.
7
Date Recue/Date Received 2021-08-26
100581 The housing of Figures 1-2 includes four sides walls 11, a roof
comprising four sloped
portions 12 and 13, which are continuous with the four sides walls 11,
respectively, an opening
14 in roof portion 13, and an overhang (or eve) 15. Roof portion 13 and the
overhang 15
cooperate to form the external exposure opening 16. There is an optional pull
protective cover
17 that is intended to protect the external exposure opening 16 from blown
insulation
penetration. Line 12A is a maximum fill height caution marker. As used herein,
the term "eve"
refers to an overhang formed from, or extending directly from, a portion of a
roof.
[0059] The housing of Figures 1-2 is substantially square in horizontal cross-
section. Other
shapes are contemplated, especially those with other polygonal cross-sections,
but a rectangular
shape is currently thought to provide the greatest volume of air horizontally
surrounding the
lighting can. In most preferred embodiments, the edges of the housing are
beveled. Beveled
housing edges are thought to increase strength of the housing, while only
minimally reducing
seal effectiveness. In addition, beveled corners allow the housing to fold
into a relatively flat
configuration with minimal compression and distorting of the insulation and
housing materials
and allows for the use of straight-cut internal panels, thus allowing for
easier shipment.
Furthermore, beveled edges reduce insulating and housing materials used,
significantly lowering
production costs and minimizing impact on the environment. The sides can have
air holes (not
shown), although such side holes are thought to be less desirable.
[0060] Each of the housings described herein can be made of any suitable
material or materials.
Contemplated materials for the walls include aluminum and/or other sheet
metal, fire resistant
cardboard, foiled cardboard, foiled foam board, gypsum board, mineral fiber,
wire frame
structure and rigid fiberglass. Such walls can be made of a single material,
such as wallboard or
gypsum that provide adequate insulation. Alternatively or additionally, one or
more of the walls
can be constructed of a paper or other panel lined with one or more sheets or
mats of fiberglass
or other insulation material. Foiled rigid fiberglass may have advantages such
as; fire resistance,
insulating, strength, durability, partial flexibility, manufacturing labor
savings and workability.
Those features are considered particularly helpful during on-site fitment and
installation around
obstacles such as wires, fixture housing brackets and framing members.
8
Date Recue/Date Received 2021-08-26
100611 Thus, the housings of Figures 1, 3, 4, 6, 7 and 8 should all be
interpreted as including
myriad possible options, including a first option that each of the walls and
roof portions
comprises a paper, wire or other skeleton to which fiberglass or other
insulating mats are
attached on an inwardly facing side, and a second option in which each of the
walls and roof
portions comprises fiberglass or other insulating mats that are sufficiently
rigid to form the
housing without relying on any supporting skeleton.
[0062] Each of the housings described herein are also contemplated to have
open bottoms. As
used herein, the term "open bottom" means at least 70% open. Thus, a housing
having a bottom
sheet with a large central hole would still be considered to be an open bottom
housing as long as
the area of the hole is less than 30% of the area that could be occupied by
the bottom sheet.
Nevertheless, it is preferred that the bottom of the housings are completely
open, i.e., there is
substantially no extension of the side walls towards the center of the bottom
of the housing.
100631 Figures 3, 5, 6, and 7 show an alternate housing 100 in which two of
the roof portions
are vertical, and another two of the roof portions are sloped. Here there are
four sides walls 101,
a roof comprising two sloped portions 102 and 103, which are continuous with
two of the side
walls 101, respectively, an opening 104 above roof portion 103, and an
overhang (or eve) 105.
Roof portion 103 and overhang 105 cooperate to form the external exposure
opening 106.
100641 Figure 4 shows the same enclosure in an opened configuration, such as
could be seen
during manufacture.
[0065] Figure 5 shows the same enclosure in a partially assembled
configuration. Roof side
portions 102 and 103 have not yet been brought into juxtaposing contact.
100661 Figure 6 shows the same enclosure with an optional baffle 103A, and
also depicts two
joists 107, the portion of a lighting can 108 that extends above the ceiling
110, an electrical box
109, and wiring 111. Figure 6 further shows tie downs 150, which should be
viewed as being
stapled or otherwise attached to the joists 107. Similar tie downs can be
added to any of the
other housings contemplated herein.
[0067] Figure 7 is a vertical cross section of the housing of Figure 3,
showing contemplated air
flows 120, 122, 124, and 126.
9
Date Recue/Date Received 2021-08-26
100681 Figure 8 is a perspective view of an alternative housing 200, once
again having four
walls 201, and here having four sloped roof portions 202, roof openings 211,
MylarTM or other
heat activated membrane cover 214, and an optional cap/cover and retainer 210
capable of
holding/retaining loose insulation, the top of which is depicted by line 212.
100691 Components exposed to potentially cold air are insulated and can be
sloped to prevent
cold penetration. A sloping top directs heat/cold and greatly reduces the
surface area (when
properly covered with insulation) exposed to external temperature conditions.
Figure 8
combines an inward sloping top and one or more vent openings 211. Hot/cold can
be further
managed via the use of a heat-activated membrane cover (which in this case is
flap 214), which
covers the openings 211 until sufficient heat buildup causes lifting the flap,
thus allowing heat to
escape.
[0070] Figure 9A, 9B, and 9C illustrate venting through dimensional insulating
material of roof
portion 202. It is contemplated that air flow can be managed and directed by
opening size,
orientation angle, quantity, etc. or any combination thereof For example,
Figure 9A illustrates a
diagonal opening 204 that functions as a baffle and provides more
'restrictive' venting
management than 9B or 9C. Principle dynamics that hot air rises and cold air
falls are used to
manage, direct, and regulate the rate of heat/cold loss and gain. Control also
can be achieved by
use of at least one opening and/or baffle panel and the desired effect can be
achieved by
combination of materials, slope, opening size and configuration. For example,
a flat baffle panel
with a small air escape opening will entrap greater heat than a sloped baffle
that allows heat to
more freely travel upward and escape. Likewise, the final "air mixing" chamber
can control
heat/cold, by means as simple as reducing the opening size, or by sloping an
'exit" panel to limit
the escape of hot air and the penetration of cold.
[0071] Figure 9C shows that hot air flow lifts (opens) the heat activated
membrane cover 214
until temperature stabilizes. Level line 213 is shown for reference.
100721 Contemplated housings can be in a kit form of separate parts, "pre-
hinged" parts that
unfold for easy assembly, partially assembled components, fully assembled or
any combination
thereof Final assembly can include the use of fasteners, tape or similar
adhesives as well as
connecting joinery and parts that secure the structure when assembled. Base
and top can be
Date Recue/Date Received 2021-08-26
integral parts or a combination of parts and materials. Guide lines and/or
scored lines can be
included as an aid for fitment; for example, when trimming for framing,
wiring, and fixture of
brackets. Square or rectangular configurations can provide greater internal
air volume and thus a
larger heat diffusion area; however, cylindrical configurations, hexagon and
other shapes are
acceptable, providing that clearance requirements from the heat source are
met. Other
embodiments can include collapsible frames covered with acceptable materials
or assembled
units, tapered to allow for nesting and reduce packing and shipping volume.
[0073] Figure 10 is a plan view of a panel 220 of material that forms the
walls and roof of the
housing of Figure 8. Fold lines are depicted with numeral 215. Sheet 220 could
be cut
(stamped) and scored to allow for desired folding and assembly. When
constructed of rigid foil
faced (duct use type) fiberglass material, score lines 215 would leave foil
surface intact to act as
a connecting "hinge". External strapping, fasteners or the like can be
employed to complete the
assembly. Currently, panels of cardboard are preferred because they are
inexpensive to
manufacture, lightweight, provide sufficient durability and rigidity, and form
a casing to which
mats of fiberglass can be attached in a relatively easy manner, using
fasteners as described
below. Where cardboard or other flammable materials are used as or in the
panels, it is preferred
that the panels have casing a spontaneous open air combustion temperature
between 350 F and
500 F (about 177 C and 260 C), inclusive, more preferably at least 400 F
(about 204 C) and
most preferably at least 450 F (about 232 C).
[0074] Figure 11 shows how a large sheet of material 230 could be cut to
produce multiple
copies of the panel 220 of Figure 10.
100751 In Figure 12 is a die cut cardboard or other foldable sheet material
forming a panel 301,
which can be folded and fastened to a similar panel 301 to configure housing
300 (See Figure
13). Panel 301 has fold lines 312a, locating/fastening holes 312b for secure
internal rigid
fiberglass (or suitable material) to provide added support, fire resistance
and insulation, a vent
opening 312c, which could be punched out by an installer, optional
perforations 312d wherein
material is removed and folded in a manner to secure an insulating panel over
the vent opening,
fastening holes 312e, fastening slots 312f, optional straps 312g for securing
the installed housing
300 to joist or other objects (not shown), optional washers 312h, an optional
hole 312i for aiding
11
Date Recue/Date Received 2021-08-26
removal of vent blocking material, useful when cover is removed after
installation and/or
surrounding with external insulation, and a hole 312j for attaching optional
membrane cover (not
shown).
[0076] In Figure 13, the assembled housing further includes a vent cover area
312L created by
folding/connecting panels 301, a fiberglass (or comparable) material attached
to the inside of
panel 301, with an extension portion 312m extending below the bottom edge of
panel 301, which
allows for better fitment around whatever fixture (not shown) is used to
position the lighting can
(not shown), and a fold over panel 312p that can be fastened with arrow type
clips (not shown) to
create a tension resistant joint-seam capable of maintaining tight corner
seams/connections and
allowing internal panels to compress and better seal together without
separating joint-seam.
A tie down 350 is shown as being attached to a side wall of one of the panels
301.
[0077] Of especial interest here is that in this embodiment, the housing 300
has four walls with
beveled edges 320, two of which are shown in the figure. Also of interest is
that the extension
portion 312m has a cutout 312q, which could be a hole, a tab, or simply a
slot, through which a
wire 312r could conveniently pass. Depending on the material(s) used in the
walls, such holes,
tabs or slots could be cut by an installer. In an alternative embodiment (not
shown), the
fiberglass (or comparable) material attached to the inside of the panel 301
could terminate flush
or even within the wall.
[0078] In Figure 14, yet another alternative housing 400, having walls 401,
roof portions 402,
and baffle vents 413. Inside the housing is the upper portion of a light can
490, shown in dotted
lines. The lighting can 490 preferably has a closest distance to any of the
walls 401 of at least
2.5 inches (approx 6.4 cm), and more preferably at least 3 inches (approx. 7.6
cm), or some other
distance that satisfies a local ordinance or rule. Unless the context dictates
the contrary, all
ranges set forth herein should be interpreted as being inclusive of their
endpoints, and open-
ended ranges should be interpreted to include commercially practical values.
Similarly, all lists
of values should be considered as inclusive of intermediate values unless the
context indicates
the contrary.
[0079] Here again, without wishing to be limited to any particular theory or
mechanism of
action, it is contemplated that the housing 400 is an advancement over prior
art housings at least
12
Date Recue/Date Received 2021-08-26
partially because the converging diagonal upper portions of the roof direct
heat up to at least one
opening, and also reduce the potential exposure area towards the uppermost
terminating
intersection(s).
[0080] Figure 15 is a side view of mating ratchet rivet parts for attaching
sheets of a fiberglass
or other material to panels of a housing, as in Figure 13.
100811 Figure 16 is a side view of a Christmas tree type fastener and
retaining nut for quick
connection of panels of a housing to one another, as in Figure 13.
[0082] Figure 17 is a side view of an arrow type fastener for attaching an
optional membrane
(flap) over a vent opening 214, as in Figure 8, and can also be used for
securing tension flap
312p, as in Figure 13.
[0083] Figures 18a and 18b show a side view of the beveled edge 320 of housing
300 in Figure
13. Beveled edge 320 allows insulation layers 520 and 530 to fold into a
relatively flat
configuration (Figure 18b) with little distorting of the insulating layers and
housing material.
When housing 300 is in an open configuration (Figure 18a) insulation layers
520 and 530 meet at
a joint 540 to form a sealed interior. One of skill in the art will appreciate
that the length of
beveled edge 320 and the thickness of insulation layers 520 and 530 can be
varied to achieve
different degrees of compression of the insulation layers at joint 540. The
beveled edge provides
a gap, which allows for repositioning and fitment modification when installing
the housing. The
gap further eliminates the need to trim at least one internal panel edge and
allows for a more
uniform and secure seal to joist material to prevent unwanted airflow and
migration of
surrounding insulation into the internal housing area and potentially living
space.
100841 It is contemplated that one could use different types of fasteners, box
staples, or even
glue or adhesive in place of any of the fasteners shown in Figures 15-17.
Currently, however,
the fasteners shown in Figures 15-17 are preferred because they are thought to
be cost-effective,
provide good long-term stability, have a relatively high failure temperature,
and are
environmentally friendly once in position. Many glues and adhesives, for
example, can fail at
about 200 F (about 93 C), and may produce off-gasses.
13
Date Recue/Date Received 2021-08-26
100851 Additional safety devices/features protect against heat buildup.
Housings can function
without vent(s) covers, but in the event covers are employed and heat builds
up to critical level,
additional safety features could include one or more of the following: (1) A
vent could be
covered with a heat sensitive membrane that shrinks, (melts) at a
predetermined temperature;
(2) A desired material failure could be aided by including at least one focal
point such as a hole
that allows minimal passage of air, but would expand as heat reached critical
levels and material
shrinks; (3) A cover could be installed with low-temp failure adhesive and
positioned to "fall"
away from the roof opening.
100861 From an installation standpoint, it is contemplated that a housing
contemplated herein
could be easily installed to retrofit either IC (insulation contacting) or non-
IC fixtures. Steps
would include: (1) providing a housing having an insulated first side wall, an
open bottom, and a
tapered roof; (2) placing the housing over the can such that the first side
wall is at least 3" from
the can; and (3) ensuring that the roof has at least a first opening for
egress of hot air. In
preferred embodiments, steps would also include one or more of the following:
ensuring that the
roof has an overhang over the first opening; ensuring that all portions of the
housing are at least
3" from the can; and folding back a bottom portion of the first side wall.
Where the ceiling can
is disposed near a joist, contemplated methods include attaching one or more
of the folded back
bottom portion, or a tie strip, to the joist using a fastener. Where the
ceiling can is powered by a
wire, and the first side wall defines a passage, contemplated methods include
running the wire
through the passage.
100871 It is further contemplated to distribute a blown type of insulation
about the housing, or
another other type of insulation such as blankets of fiberglass.
[0088] Contemplated production methods include stamping or cutting out panels
form cardboard
or other suitable material, as for example in Figures 4, 10, 11 and/or 12,
folding them into
housings, as for example in Figures 1, 3, 5, 6, 7, 8, 13 and/or 14, and using
fasteners as for
example in figures 15, 16, and/or 17. It is especially contemplated to ship
housings in a flattened
shipping configuration, as for example in Figure 2.
[0089] In other embodiments, the inventive subject matter includes additional
features that
permit greater pre-assembly prior to use, and/or permit use with fewer or no
additional fasteners.
14
Date Recue/Date Received 2021-08-26
In particular these embodiments provide for easy production of a complete
ready-to-install
fixture from a folded or partially folded state. For example, Figure 19
illustrates an embodiment
produced from a folded version of the present inventive subject matter. A roof
portion 600,
when folded past the vertical plane, imparts a tension on the seams of the
fixture to improve
strength and sealing of seams. The degree of angle 610 can be varied in order
to provide
additional rigidity to the fixture when in the assembled configuration.
[0090] Conveniently, the fixture can be adapted to be installed on a light
fixture bracket or track
620. In some embodiments slots 630 can be added to increase the rigidity and
stability of a
bottom fold. In non-insulation contact applications, where some airflow is
desired, one or more
vents 640 can be included in the top portion 650 of the fixture. In some
embodiments the top
portion may form an inclined or sloped surface as shown in Figure 19, or a
more flattened top as
shown in Figure 28. Where the fixture is insulation contacting, airflow may
not be desired, and
so in those cases a vent 640, may not be desired, or considered optional.
100911 Figures 20 and 22 show an embodiment of the inventive subject matter in
a partially
folded configuration. Folding is made easier by producing the fixture with
fold lines 670
disposed generally along a vertical axis of a side portion 680 of the fixture.
In effect the fold
lines 670 permit the fixture to be open and closed accordion style. In the
closed, or flattened,
configuration, the fixture takes up significantly less space, providing an
advantage for shipping
or storage. Folding the fixture after manufacture and prior to use also
provides the advantage of
affording some protection to the various surfaces of the fixture to reduce the
chance of accidental
damage during shipping or storage.
100921 Figures 21a and 21b illustrate an embodiment in the partially unfolded
and unfolded
configurations respectively. In Figure 21a, a user is shown using simple hand
pressure to pop
open the fixture by simple unfolding. Figure 21b illustrates a completely
unfolded fixture. In
some embodiments adjacent top portions can be configured to fold at a hinge
675, and to overlap
each other at an overlap region 660. Overlapping can also provide additional
rigidity to the
fixture in its assembled state. Overlapping regions can also include lapping
surfaces 690 that
could further include well known features such as slots and tabs (not shown)
to better secure a
folded joint and to aid in resistance to movement.
Date Recue/Date Received 2021-08-26
100931 Figure 23a and 23b illustrate embodiments of the inventive subject
matter in a compact,
folded configuration. The fold lines in this case are roughly diametrically
opposed so that the
structure folds substantially symmetrically upon itself. While two folds are
illustrated here, more
than two folds are compatible with the present inventive subject matter. For
example, it might be
desirable in some cases to have a plurality of folds so that the fixture could
be collapsed into a
roughly tubular shape for shipping or storage. In addition, a tubular shape
could be
advantageous when replacing fixtures in round openings, or where openings of
non-standard
sizes or shapes are encountered.
100941 Figures 24a and 24b illustrate embodiments of the inventive subject
matter as they are
initially manufactured. It is contemplated that one method of manufacture
could be to stamp, or
die cut, panels out of rolls of material using a pre-made die. In some cases
the die could stamp
units from smaller panels of material. In other cases it might be preferable
to use a roller die that
cuts roll stock of the panel material fed past the roller, and then separate
individual units in a
subsequent cutting step from. Conveniently, and as shown in these Figures, a
complete fixture
may be produced as a single piece from the desired material. The manufacturing
die or stamp
may also be designed to press in the fold-lines into the manufactured panel to
aid in later
assembly.
100951 A variety of materials are compatible for use in the manufacture of the
present inventive
subject matter. For example, foil/scrim/kraft (FSK) would be suitable to
provide ease of
handling, sufficient structural strength, and desirable properties of heat and
air penetration
resistance. An attached and/or bonded material such as fiberglass, mineral
fiber or other suitable
material having desired properties of rigidity, compressibility and/or shape
memory, could also
be used to provide the features of structural rigidity as well as heat and air
penetration properties.
[0096] Figures 25 through 31 illustrate embodiments of the present inventive
subject matter that
further include score cuts that function as hinge elements. For example in a
fixture manufactured
from FSK, the score cuts 1100A and 1100B may penetrate the fiber but not the
outer membrane
of the material. In one embodiment, a fixture constructed of 1/2" to 5/8"
glass fiber material
could include a 1/4- deep score cut 1100A to form a tensioned square corner,
and 1/8- deep
score cut 1100B to form a tensioned folded seam along the sloped upper panels.
These "hinges"
16
Date Recue/Date Received 2021-08-26
would provide the desired folding characteristics and compression properties
to the fixture when
in the assembled configuration.
[0097] Additional cuts/folds 1200A are positioned to aid in folding of the
fixture for shipping
and/or storage. As with the score cuts 1100A and 1100B, these cuts do not
penetrate the outer
membrane of the fixture material.
100981 In some cases cuts 1300 could provide additional fold lines. Depending
on the need for
structural strength versus ease of folding, these score cuts could be run part
of the length, or the
entire length of the region into which they are cut. To assist in securing and
placement of
adjacent roof portions, a male-female tab-slot alignment feature 1400 is
included at the point that
will form the peak of the roof portion. Figure 26 illustrates a partially
folded fixture where the
side portions have been folded along the score cuts, and the roof portions are
yet to be engaged
with each other. The alignment feature 1400 is shown.
100991 Figure 27 illustrates an embodiment of the inventive subject matter
where a vent has not
been included in the roof portion. In this embodiment a fold line 1500A
function as a top-joining
seam line. Fold lines 1600 are formed by score cuts shown earlier as 1200A.
[00100] Figure 28 illustrates an embodiment wherein the roof panels 1700 meet
at a flat plan
convergence, rather than at a peak or pointed junction. The roof panels can be
fashioned
according to overlap to whatever extent is required. Overlap of the roof
panels will increase the
rigidity of the fixture. Additionally, tabs or other forms of securement may
be fashioned into the
adjacent roof panels so that they can engage each other, again improving the
stability of the
assembled fixture.
1001011 Figure 29 illustrates an embodiment in a partially folded
configuration. Score cuts
1200A provide a point along which the structurally will naturally tend to
fold. As shown in
Figures 30 and 31, these score cuts can penetrate through the fiber (as in
Figure 30), but not the
outer membrane, or can be partial cuts that either do not fully extend the
length of the fixture or
do not fully penetrate the fiber portion of the material (as in Figure 31).
Where the cut is deeper,
the fiber material may be separated.
17
Date Recue/Date Received 2021-08-26
1001021 The embodiments in Figures 30 and 31 show examples of a fixture
produce using a
material with a fiber layer and outer membrane. In some cases it is possible
for the fixture to be
formed from a homogenous material, in which case the score cuts would be
interpreted to be
extending to varying degree into, but not completely through that material.
Those of skill in the
art will readily appreciate the depth of a score cut required to provide the
features of folding and
hinge function without unduly compromising the overall strength of the
assembled fixture.
[00103] Figure 32 illustrates a roller design useful in the production of
score cuts in the
material used to fashion the fixture. Figure 32 is an example of a radius
roller 1800 that permits
scoring while reducing the chance of damage to the surface of the material
either side of the
desired cut line. This tool can also be made multifunctional, and include such
things as a scraper
adapted to remove fiber from specific areas of the fixture prior to final
assembly. The roller may
also include a top handle 1700 to improve ergonomic efficiency. The roller may
also include a
quick-change mechanism to allow easy replacement of an old roller with a new
one 1800A.
1001041 Figure 33 illustrates a roller machine 1900 for use in production of
fixtures from
stock material. The machine includes a roller 1910 based on a platform 1920. A
cutting die
1930 represents the shape of the manufactured product. The stock from which
the fixtures are to
be cut could be provided either as sheets or rolls of material. The stock can
be fed either
manually, or by automated systems that are well known in the art of
manufacturing processes.
Secondary stripping can be performed during the return travel by way of a
separating die board
and actuated scraping device. Vacuum suction may be included to remove waste
and to aid in
cleaning the die surface prior to the next cutting operation. The die may
include all the shape
features of the fixture, as well as any score cuts where those are used to
provide fold and/or
hinge lines. Pressing into the stock material would provide an alternative
method to form fold
lines, rather than cutting. The die may be movable in order to adjust the
depth of the score cuts
as may be desired for different applications or when working with different
types of materials.
The die can optionally be a plate as depicted, or may be disposed along the
radius of the roller.
[00105] Embodiments of the inventive subject matter could conveniently be
offered for sale
either unassembled or partially assembled. Embodiments of the inventive
subject matter could
also be offered in an kit form, including for example, with a foldable
cardboard or other type of
18
Date Recue/Date Received 2021-08-26
form that mates with the interior dimensions of the device to aid in fast,
accurate assembly of a
fixture.
[00106] The base design optimizes volume and facilitates fitting to standard
16" on center
framing joints. However, it is readily apparent that the design of the present
inventive subject
matter is adaptable such that any style of framing could be accommodated. In
particular, the
inventive subject matter is well adapted for use in tight spaces, such as near
roof rafter pitches, or
where the placement is near an eave. In addition, the angled top portion can
be varied in position
to adapt a fixture for placement in tight attic spaces where room above the
fixture is limited.
Conveniently, the roof portion of the fixture can be partially collapsed if
desired without
comprising the integrity of the rest of the fixture.
[00107] The inventive subject matter provides an easy to use, stable
barrier that provides the
necessary separation between the fixture and the surrounding insulation. The
design takes
advantage of outside pressure exerted by the weight of the surrounding
insulation to ensure
tightness of seams and the base seal on the substrate, without the need for
caulking, expanding
foam, tapes, or other adhesives.
[00108] It should be appreciated that the numerous embodiments disclosed
herein can be used
or adapted for use with either IC light fixtures or non-IC light fixtures. The
inventive subject
matter is not intended to be limited by any particular category of light
fixture. Depending on the
application (e.g., type of light fixture, heat generated by the bulb,
environmental temperatures,
surrounding materials, etc) openings can be included in the barrier housing to
achieve the desired
barrier characteristics.
1001091 It should be apparent to those skilled in the art that many more
modifications besides
those already described are possible without departing from the inventive
concepts herein. The
inventive subject matter, therefore, is not to be restricted except in the
scope of the appended
claims. Moreover, in interpreting both the specification and the claims, all
terms should be
interpreted in the broadest possible manner consistent with the context. In
particular, the terms
"comprises" and "comprising" should be interpreted as referring to elements,
components, or
steps in a non-exclusive manner, indicating that the referenced elements,
components, or steps
may be present, or utilized, or combined with other elements, components, or
steps that are not
19
Date Recue/Date Received 2021-08-26
expressly referenced. Where the specification claims refers to at least one of
something selected
from the group consisting of A, B, C .... and N, the text should be
interpreted as requiring only
one element from the group, not A plus N, or B plus N, etc.
Date Recue/Date Received 2021-08-26
