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AU2013100156B4 - Flexible light fitting - Google Patents

Flexible light fitting Download PDF

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Publication number
AU2013100156B4
AU2013100156B4 AU2013100156A AU2013100156A AU2013100156B4 AU 2013100156 B4 AU2013100156 B4 AU 2013100156B4 AU 2013100156 A AU2013100156 A AU 2013100156A AU 2013100156 A AU2013100156 A AU 2013100156A AU 2013100156 B4 AU2013100156 B4 AU 2013100156B4
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AU
Australia
Prior art keywords
fitting
light
light fitting
ceiling
bulkhead
Prior art date
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Expired
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AU2013100156A
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AU2013100156A4 (en
Inventor
Kenneth David Cleine
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Individual
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Individual
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Priority to AU2013100156A priority Critical patent/AU2013100156B4/en
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Publication of AU2013100156A4 publication Critical patent/AU2013100156A4/en
Publication of AU2013100156B4 publication Critical patent/AU2013100156B4/en
Anticipated expiration legal-status Critical
Expired legal-status Critical Current

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Abstract

A non-metallic building industry light fitting manufactured from silicone rubber or similar flexible material capable of withstanding highly corrosive environments. The preferred embodiment of the invention is in the form of an annular grommet (10) moulded from a single homogeneous piece of flexible material capable of withstanding high operating temperatures. The grommet (10) is preferably electrically insulating as well as being weather and chemical resistant. The light fitting is manually deformable for installation into a complementary opening (12) in a ceiling, bulkhead panel or similar (16), whereafter the deformation of grommet (10) returns to its undeformed shape upon release. A light bulb (14) is adapted to fit into and be retained by the light fitting (10) by deforming and releasing same whereby the light bulb is retained by the shape (13) and resilient properties of the light fitting.

Description

FLEXIBLE LIGHT FITTING TECHNICAL FIELD [0001] This invention relates to building industry electric lighting and can be suitably described as a "light fitting". In this industry, a "light fitting" is generally accepted as a fixture or assembly designed to house an electric light "globe" or "bulb" depending on one's choice of terminology. Such fittings usually offer a safe means of housing a light bulb as well as providing it with both a safe electrical connection and convenient access to change or replace the light bulb. Use of the word "bulb" is used throughout and means an electric light bulb or globe. [0002] This invention was developed originally to provide the market with a completely corrosion proof light fitting however, it will be appreciated that the invention may be used in numerous applications aside from where high resistance to corrosion is a key factor. The invention, by way of its innovation and novel design provides an economical alternative to the range of light fittings currently available and yet is in many ways a far superior product to some existing art. BACKGROUND ART [0003] Manufactures associated with the domestic and commercial lighting industry continually provide their retailers with an ever changing array of light fittings. Fashion and style determine a need for changing designs and it may be considered that a consumer demand for varying aesthetics plays a large role. Advancements in technology provide the industry with more compact and more efficient forms of light bulb and accordingly the humble light fitting is forever changing to accommodate. [0004] A specific lighting application may determine the need for a light fitting design that is specifically suited to that particular application such as a light fitting that will effectively operate within the harsh confines of a high-temperature, commercial oven or a light fitting that functions well while submerged below water in a pond or swimming pool. [0005] Among the specific environments requiring specially designed light fittings are the coastal, tropical regions of the world which provide some of the harshest conditions under which light fittings are expected to function. [0006] One common term for ceiling-mounted lights in a home is "down lights", as these lights generally illuminate in a downward direction in relation to the horizontal plane of the ceiling. Although the invention has been primarily developed as a "down
I
light", it will be appreciated that it may be installed in any desirable orientation within ceilings, walls, bulkheads or panels situated in any plane. [0007] Low-voltage "tungsten halogen" light bulbs, as they are commonly known, have appeared over the past few decades as an alternative to the previously well known incandescent light globes that have been the standard lighting in homes for over a century. [0008] More recently, "Light Emitting Diode" (LE.D) light bulbs have been introduced in parallel with modern advances in technology. [0009] In much the same way as the first "low-energy" light bulbs were designed to fit into existing light fittings present in millions of homes around the world, the designers of LED light bulbs have made styles of LED bulb that will fit into light fittings and light bulb holders that were originally designed to accept tungsten halogen bulbs, thus negating the need to introduce a complete new range of light fittings and light bulb holders to accommodate the newer technology light bulbs. [0010] One known class of light bulb is an internationally popular shape and style of bulb known in the industry as the "MR1 6" lamp that features a standard, universal shape and size however, it is available in several technology types including both high and low-voltage tungsten halogen as well as LED. [0011] Due to the common occurrence and popularity of the MR16 style of light bulb, development work to date related to this invention has been carried out using this style of bulb however, it will be appreciated that a range of other styles of light bulb may be utilised with this invention or the invention utilised with other styles of light bulb. [0012] In conditions where an externally located light fitting is exposed to strong salt laden winds carrying moisture, high temperatures and humidity levels reaching 100% in combination with salt residues, many currently available light fittings sold as "outdoor light fittings" simply fail prematurely under such conditions. [0013] One class of known art is manufactured from steel which has been surface treated by way of commercial powder coating. This method of finish coating invariably fails under such extreme climatic conditions and rust, from the underlying corroding steel, appears rapidly after initial installation and quickly consumes the light fitting to a point where it becomes unsafe and unserviceable. [0014] Another known class of outdoor light fitting is manufactured from cast aluminium alloy and usually these fittings are also surface treated by painting or powder coating however the same inherent problems occur due to the inability of the surface treatment to withstand the harsh, extremely corrosive conditions over time. [0015] Corrosion problems caused by electrolytic action can occur with aluminium alloys and other metals being used as the body of the outdoor light fitting as high 2 levels of moisture and salt, combined with dissimilar metals, can produce an electrolytic (electrochemical or voltaic) action. Differing metallic materials used to manufacture the light fitting, such as brass or stainless steel, or a mounting surface of galvanised iron or Zincalume TM, commonly used as building materials, can initialise and support a detrimental electrolytic action, as previously described, that will lead to corrosion of the light fitting, the metallic mounting surface, or both. [0016] Another known class of outdoor light fitting is of a type manufactured from stainless steel. This class of fitting is often advertised and promoted as being suitable for outdoor use exposed to the elements in harsh coastal conditions where moisture and salt laden atmospheres prevail. It should be noted however that some variation in quality occurs within this class of fitting and unless regular maintenance is applied rust staining may still occur even in fittings manufactured from 316 grade stainless steel. Aside from this aesthetic problem the cost of purchasing such fittings is usually high. [0017] The less expensive stainless steel fittings often have non-stainless steel components in their assembly including the spring clips that retain the light fitting into the mounting surface and these non-stainless steel parts quickly corrode and fail in the harsh conditions rendering the entire light fitting unserviceable within a relatively short span of time. [0018] In conclusion it can be reasonably stated that very few of the currently available light fittings designed for outdoor installation in the harsh coastal conditions noted previously, will effectively endure such conditions over the long term -many not being able to maintain their operational integrity even within the short term. [0019] High levels of heat produced by the operation of some light bulbs can have a detrimental effect upon the useful life of the light fitting. In particular, the high temperatures produced when tungsten halogen bulbs are operating can cause premature deterioration of the light fitting and its surface coatings. [0020] Some known examples of light fitting comprise of complicated assemblies made up of many components and sub-assemblies making them over complex and often expensive due to elaborate manufacturing requirements. [0021] Some known examples of light fitting are more difficult to install than others and in most cases the method of mounting the light fitting to a surface or substrate requires using some form of fastener or spring clip and these items are often the weak component that fails under harsh conditions. [0022] Some known examples of light fittings are manufactured from electrically conductive metal which may increase the level of risk associated with contacting electricity, particularly if poor earthing or a wet environment is present. [0023] Despite the fact that a specific range of light fittings have, according to their manufacturers, been specifically designed to withstand the harsh conditions of a 3 tropical, coastal environment, only few of these in reality are in fact capable of providing a worthy, long term service of operation without failure or degradation. SUMMARY OF INVENTION [0024] In accordance with a first aspect the present invention provides a building industry downlight or recessed light fitting, adapted to removably mount a light bulb in a ceiling, bulkhead or the like, said fitting being manufactured from a flexible, non corrosive and resilient material adapted to be deformed and return to its original shape during secure fitment of the light fitting to a complementary opening in the ceiling, bulkhead or the like and adapted to be deformed during fitment or removal of a light bulb into a complementary shaped opening of the fitting whereby the light bulb is resiliently retained by the complementary shaped opening of the fitting and mechanical properties of the material of the light fitting. [0025] In a second aspect the present invention provides a method of mounting a light globe holder in a ceiling, bulkhead or the like, said method comprising mounting a building industry downlight or recessed light fitting, formed from flexible, non corrosive resilient material adapted to return to its original shape, by manually deforming the light fitting while placing the fitting in a complementary opening in the ceiling, bulkhead or the like and allowing the fitting to return to its original shape within the complementary opening to be retained by the ceiling, bulkhead or the like before positioning a light bulb into a complementary shaped opening of the fitting whereby the light bulb is retained by the shape of the opening in the light fitting and the mechanical properties of the material of the fitting. [0026] In development of the present invention corrosion was the first problem to ameliorate and the prime motivation for development of this invention. The mandate was to provide a light fitting that would not corrode even under the harshest of climatic conditions and preferably capable of withstanding the high operating temperatures associated with some types of light bulb, particularly tungsten halogen bulbs which operate at extremely high temperatures. After conducting extensive research, and trials using various manufacturing materials, the best solution finally came in the form of high-temperature resistant silicone rubber compounds from which to make a light fitting. These advanced materials carry all of the properties necessary to overcome many problems of prior art and currently available light fittings. [0027] The particular heat resistant silicone rubber chosen for prototypes was one of many such advanced materials commercially and readily available. It can be easily moulded to practically any shape, is impervious to corrosion and will not suffer in any detrimental way from exposure to the weather and elements of the weather. It is relatively inexpensive, is not affected by elevated temperatures over a long duration and has a range of very commendable mechanical properties. [0028] Of further benefit, this preferred material is not electrically conductive and therefore, as a good insulator, risks associated with electricity are reduced. Being electrically inert also overcomes any problems associated with electrolysis. 4 [0029] The preferred material requires no ongoing maintenance to ensure optimum performance and is aesthetically pleasing given that it can be prepared in a range of colours, surface finishes and hardnesses without the need for any surface coating or surface treatment. [0030] Utilisation of the preferred material in combination with prudent design practice has resulted in a simple, one-piece fitting that requires no other fixing components, fasteners or hardware to complete a light fitting installation. [0031] The lack of complexity of design and use of the preferred material allows a very economical light fitting to be produced. [0032] The present invention serves to improve in many ways upon the designs of the vast range of proprietary light fittings currently available with the most notable attribute being its simplicity of design. [0033] This invention results in a flexible light fitting manufactured from one homogenous piece of flexible material that can be simply made. [0034] Embodiments of the present invention result in a light fitting capable of housing the industry standard "MR16" style of light bulb while in its broadest aspect is not limited to this particular style or configuration of bulb. [0035] Preferred embodiments of this invention provide a light fitting adapted to withstand the harsh conditions of tropical, coastal regions while being suited to use in other climatic regions. [0036] Unlike much of the known art, a preferred light fitting of this invention will not rust, corrode or otherwise deteriorate prematurely because of exposure to a range of environments including but not limited to water, sun, wind, ultraviolet light, salt laden atmospheres, heat, cold and humidity. [0037] Similarly, a preferred light fitting of the invention will not rust, corrode or otherwise deteriorate prematurely because of exposure to a range of chemicals or chemical rich atmospheres making it extremely durable and suited to a range of commercial and industrial applications. [0038] Preferred embodiments of this invention have no surface coatings or treatments that may deteriorate over time. [0039] Light fittings of this invention are preferably manufactured from material that is electrically insulating thereby negating any risk of deterioration due to electrolytic action. [0040] Preferred embodiments of the invention require no additional components, hardware or fasteners for the purpose of mounting to a ceiling, bulkhead or otherwise a supporting substrate. 5 [0041] Embodiments of the invention provide a light fitting that is adapted for an extended operating life in harsh conditions but will perform equally well when used under normal conditions. [0042] Preferred embodiments of this invention provide a light fitting adapted to withstand the high operating temperatures associated with tungsten halogen bulbs over an extended period of time without any significant detriment while also performing equally well will other types of bulbs, such as LED bulbs. [0043] Preferred light fittings of the invention can be made inexpensively to produce a high-performance, low cost light fitting. [0044] Being manufactured from a suitable flexible material allows preferred embodiments of a light fitting of the present invention to be temporarily deformed by hand for the purpose of installation in an opening or cutout in much the same way as a rubber bulkhead grommet is installed. [0045] Embodiments can be designed to provide a water tight seal between the light bulb and the fitting as well as between the fitting and the opening in a bulkhead or panel into which the fitting is adapted to be installed. This adaptation provides a light fitting with the ability to easily meet various standards that govern the ingress of moisture associated with electrical appliances such as an IP55 or an IP65 rating as examples of one type of said standard. Brief Description of the Drawings [0046] The present invention will now be described by way of example with reference to the accompanying drawings, in which: [0047] Figure 1 is a plan view of a preferred embodiment of a light fitting in accordance with the present invention; [0048] Figure 2 is the cross-sectional view Z-Z of Figure 1; [0049] Figure 3 is the same as Figure 2 showing a light bulb mounted in the light fitting; and [0050] Figure 4 is a similar view to that Figure 3 with the light fitting mounted in an opening in a planar sheet or panel. BEST MODES [0051] The light fitting embodiment 10 as shown by Figures 1 - 4 depicts an annular shaped article with a circular recesses 11 around its perimeter for mounting into an opening 12 in a ceiling or the like and with a central opening 13 adapted to fit and resiliently retain a replaceable light bulb or globe 14. [0052] The light fitting 10 shown in the drawings is moulded from a flexible resilient material that can be formed to relatively precise dimensions to complement the 6 shape and contouring of the exterior of globe 14 (Figures 3 and 4). This globe fitting opening 13 is adapted to locate and securely retain globe 14. [0053] Figure 3. shows a dimension 15 which is a diameter measurement that corresponds in a close ratio with the cut-out hole or void 12 in ceiling, bulkhead or panel 16 that is formed to mount light fitting 10. Similarly, the dimension 17 corresponds to fitment of the thickness 18 of ceiling, bulkhead or panel 16 into which circular recess 11 of fitting 10 is mounted. [0054] The globe 14, as shown in the drawings, corresponds to the popular MR16 style of light bulb however it will be appreciated that embodiments of the present invention can be formed to accommodate numerous other styles of light bulb. It will also be appreciated that both the outer and inner shape of a light fitting of the present invention can be moulded in a range of shapes or aesthetic appearances. [0055] The illustrated embodiment of the invention comprises an annular shaped grommet that serves as both the lamp holder and the light fitting, however, it will be appreciated that a range of different shapes could be easily adopted. [0056] Normal installation of a downlight, as these fittings are commonly known, typified by the drawings involves first cutting or sawing a hole, usually a circular hole 12, in the ceiling, bulkhead or panel 16. Such hole is adapted to accommodate a down light fitting. [0057] Some variation in thickness can be expected across the range of differing types of material that ceilings, bulkheads and wall panels 16 are made from. Generally, such thickness may vary from 4mm to 6mm in the case of fibre reinforced cement sheets and up to 10mm to 12mm in the case of dry wall and plasterboards such as Gyprock TM. Such variation is easily accommodated both by varying dimension 15 and/or relying upon the flexibility of the material of light fitting 10 to accommodate a limited range of material thickness of dimension 17. It is anticipated that approximately two models of the fitting will accommodate all common ceiling thicknesses by relying upon the resilience and flexibility of a preferred material. [0058] Preparation for installation of a down light fitting includes installation of electrical wiring which must be carried out within the ceiling cavity allowing for expedient connection of a light fitting to the said pre-wiring and the installation of the light fitting within the hole that has been cut into the panel. [0059] There is no difference to existing ceiling preparation processes regardless of whether a down light fitting of the prior art or the present invention is to be installed. Instead of the light fitting being retained in the panel by way of screws, spring clips or other types of fastener, the present invention requires none of that hardware to facilitate mounting of the light fitting. [0060] Furthermore, light fittings of the present invention may be used as a retrofit or replacement for existing prior art light fittings that may be inferior or have failed. 7 [0061] Preferred embodiments of the present invention are manufactured from a flexible material which allows the light fitting to be temporarily deformed by hand for the purpose of installation in much the same way as a rubber bulkhead grommet is installed. The inherent memory of the material causes it to return instantly to its original moulded shape after being deformed by hand for the purpose of installation and then released. In a similar way, the flexible fitting may be temporarily deformed to facilitate installation of the light bulb. Once installed, both the form of the moulded fitting and/or the elastic strength of the moulded fitting will retain the light bulb securely in place as well as anchoring the flexible light fitting securely into the opening 12 within a ceiling, bulkhead or mounting panel 16. 8

Claims (5)

1. A building industry downlight or recessed light fitting, adapted to removably mount a light bulb in a ceiling, bulkhead or the like, said fitting being manufactured from a flexible, non-corrosive and resilient material adapted to be deformed and return to its original shape during secure fitment of the light fitting to a complementary opening in the ceiling, bulkhead or the like and adapted to be deformed during fitment or removal of a light bulb into a complementary shaped opening of the fitting whereby the light bulb is resiliently retained by the complementary shaped opening of the fitting and mechanical properties of the material of the light fitting.
2. A light fitting as claimed in claim 1, wherein the material is electrically non conducting.
3. A light fitting as claimed in claim 1 or 2, when moulded as a single piece from a heat resistant silicone rubber.
4. A method of mounting a light bulb in a ceiling, bulkhead or the like, said method comprising mounting a building industry downlight or recessed light fitting, as claimed in any one of the preceding claims, by manually deforming the light fitting while placing the fitting in a complementary opening in the ceiling, bulkhead or the like and allowing the fitting to return to its original shape within the complementary opening to be retained by the ceiling, bulkhead or the like before positioning a light bulb into a complementary shaped opening of the fitting whereby the light bulb is retained by the shape of the opening in the light fitting and the mechanical properties of the material of the fitting.
5. A method as claimed in claim 4, wherein the fit between the light fitting and the ceiling, bulkhead or the like provides a water tight seal. 9
AU2013100156A 2013-02-15 2013-02-15 Flexible light fitting Expired AU2013100156B4 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2013100156A AU2013100156B4 (en) 2013-02-15 2013-02-15 Flexible light fitting

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Application Number Priority Date Filing Date Title
AU2013100156A AU2013100156B4 (en) 2013-02-15 2013-02-15 Flexible light fitting

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AU2013100156A4 AU2013100156A4 (en) 2013-04-04
AU2013100156B4 true AU2013100156B4 (en) 2013-10-31

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Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2924338A1 (en) 2014-03-28 2015-09-30 Flowil International Lighting (HOLDING) B.V. Apparatus securing device

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3067974A (en) * 1960-08-09 1962-12-11 Truck Lite Co Rubber mounting grommet for truck light
US3225189A (en) * 1962-10-15 1965-12-21 Key Machine Tool Corp Lamp mount
US5386356A (en) * 1993-04-12 1995-01-31 Davis, Jr.; Zell Weatherproof electric lighting fixture
US7061169B1 (en) * 2004-04-22 2006-06-13 Fung Duncan C Impact and corrosion resistant lamp holder
US20070183154A1 (en) * 2006-02-04 2007-08-09 Robson Christopher M Sealed cover for recessed lighting fixture

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3067974A (en) * 1960-08-09 1962-12-11 Truck Lite Co Rubber mounting grommet for truck light
US3225189A (en) * 1962-10-15 1965-12-21 Key Machine Tool Corp Lamp mount
US5386356A (en) * 1993-04-12 1995-01-31 Davis, Jr.; Zell Weatherproof electric lighting fixture
US7061169B1 (en) * 2004-04-22 2006-06-13 Fung Duncan C Impact and corrosion resistant lamp holder
US20070183154A1 (en) * 2006-02-04 2007-08-09 Robson Christopher M Sealed cover for recessed lighting fixture

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