METHOD FOR MANUFACTURING THE CEILING LIGHTING PORTALAMP
Field of the Invention This invention relates, in general, to industrial ceiling lighting fixtures and to the manufacture thereof. BACKGROUND OF THE INVENTION There is a wide variety of industrial ceiling lighting fixtures, which meet needs such as the lighting of factories and warehouses and the like, and a great deal of progress has been made over the years. However, the existing industrial ceiling lighting fixtures have a number of problems and deficiencies, and it is to these problems and deficiencies to which this invention is directed. One problem that affects is that certain industrial ceiling lighting fixtures of the prior art are of difficult-to-handle shape and size, which makes their manufacture difficult and expensive. More generally, the high cost and complexity of manufacturing are problems of particular importance to manufacturers. In the prior art, a variety of industrial ceiling lighting fixtures is manufactured using costly die-cast housing, and in REF. 146810 In some cases, complex accommodations are used to achieve different objectives. In some cases, several external parts are required in order to support the electrical components; these structures once again do not provide a pleasing appearance on a ceiling lamp for industrial lighting. This invention addresses these problems and deficiencies. OBJECTIVES OF THE INVENTION One objective of this invention is to provide an improved method for the manufacture of industrial ceiling lighting fixtures that overcomes some of the problems and deficiencies of the prior art. Another object of this invention is to provide a simple manufacturing method for an industrial ceiling lighting fixture that has all the components enclosed within a single housing. Another object of this invention is to provide a simple manufacturing method for an industrial ceiling lighting fixture which has a low profile and which is compact and pleasing in appearance. Another object of this invention is to provide a simple manufacturing method for an industrial ceiling lighting fixture that is free of any of the external components related to the power supply and any component support structure. Another object of this invention is to provide a simple manufacturing method for an industrial ceiling lighting fixture that does not involve the use of an expensive die-cast housing. These and other objects of the invention will be apparent from the following description and from the drawings. SUMMARY OF THE INVENTION The invention is a method for the manufacture of industrial ceiling lighting fixtures of the type that includes a housing, the components related to the supply of electrical energy, (for example, a reactor, a capacitor and a cigarette lighter or electrode). of ignition) secured within the housing and a receptacle in a receptacle assembly secured in the housing. The method of this invention is an improvement over the prior art manufacturing methods for this type of lighting fixture. The method of this invention includes the following steps: Before the assembly begins, an upper housing member is formed, this upper member has a horizontal upper wall (having one or more portions) with bra-receptors thereon and a surface inside. In the same way, a lower housing member is shaped for a forced clutch with the upper member. Then, with the components related to the supply of electrical energy and any of the other components at hand we proceed with the assembly. The assembly involves placing the upper member in a generally inverted orientation on a work support structure, with the inner surface of the upper member facing up. Then, each of the components related to the supply of electrical energy, for example, the reactor, the capacitor and the ignition electrode, is generally placed on the interior surface of the upper wall which faces upwards in its position that is intended. Then, these components are secured to the inner surface of the upper member by the clutch of fasteners in a common direction with a set of fastener receivers in the upper wall. In other words, the fasteners are applied in one direction to join these components with the inner surface of the upper member. The assembly continues when the lower member is placed on the upper member in an inverted orientation. Then, the lower member is secured in the upper member to substantially complete the mounting of the lamp holder. When the assembly is complete, the lampholder is removed from the support structure. Preferred embodiments also include positioning the receptacle assembly on the interior top wall surface, and hereafter, securing the receptacle assembly on the interior top wall surface by clipping the fasteners in the common direction with another assembly of receivers for upper wall bra. The positioning and securing steps with respect to the receptacle assembly are generally more preferable in the same time as the positioning and securing steps with respect to the components related to the power supply. In preferred embodiments, the securing of the lower housing member in the upper housing member is by the clutch of fasteners in the common direction with additional receivers for fastener in the upper member. Preferably, the upper member fastener receivers are threaded holes and the fasteners clutched therewith are screws. In certain preferred embodiments, the lower housing member has a horizontal bottom wall with an exterior surface and a plurality of receivers for a bottom wall fastener therein, and the method further includes the steps of placing a reflector on the exterior surface of the housing. the lower wall in an inverted orientation and the securing of the reflector in the lower member by the clutch of fasteners in the common direction with the receivers for lower wall fastener. All of the fastener clutch movements referred to above have been done in one direction and in a downward direction, which significantly facilitates the manufacturing process. Preferably, the receivers for lower wall fastener are downward projections included in the lower wall and it is preferred that the shaping of the lower member includes the stamping operation to form the projections. It is preferred that the shaping of the upper member includes the formation of a central upper wall portion and a pair of lateral upper wall portions, which are on the opposite sides of the upper upper wall portion and are vertically displaced therefrom. . Preferably, the top wall fastener receivers are located above the upper side wall portions, so that the securing of each of the components related to the electrical power supply, and the receptacle assembly, when this is placed in the same way, either by means of the clutch of fasteners with the fastener receivers in both sides of the upper side wall. When assembled in this way, the components related to the electrical power supply are bypassed or bridged between the lateral top wall portions, through the central upper wall portion. Preferably, the shaping of the upper member also includes the formation of downwardly extending side wall portions, which are integral with the top wall portions, these side wall portions include two opposite end walls, each of which is extends downward from the top wall and ends in an end flange. The end flanges have additional receivers for fastener therein, preferably one for each flange. The shaping of the lower member includes the formation of a bottom wall and upwardly extending sidewall portions, which are integral with the bottom wall and which, together with the sidewall portions extending downward, complete the side walls for accommodation. The bottom wall has fastener holes in it, which are aligned with the fastener receivers in the end flanges of the upper member side wall portions, facilitating the aforementioned clutch.
More preferably, the shaping of the upper member includes bending a piece of sheet metal to form the joints or joints between the top wall and the side wall portions thereof, and shaping the lower member includes the fold of another piece of sheet metal to form the joints or joints between the top wall and the side wall portions thereof. Broadly speaking, the method of this invention includes: (1) shaping the upper and lower housing members for the clutch forced together to form the housing, each of the housing members having a horizontal wall with an inner surface, the horizontal surface of a first member of the housing members has bra receptors therein; (2) the positioning in a work support structure of the first housing member with its interior surface facing substantially upwards; (3) the placement of the components related to the supply of electrical energy on the inner surface of the first housing member and the securing thereof with the same by the clutch of fasteners in a common direction with a set of receivers for fastener; (4) positioning the second of the housing members in the first housing member in its forced clutch therewith; (5) securing the second housing member in the first housing member to substantially complete the mounting of the lamp holder; and (6) the removal of the lampholder from the support structure. Preferably, this widely-discussed method includes positioning the receptacle assembly of the illumination lamp holder on the interior surface of the first housing member and securing it thereto by clipping fasteners in a common direction with another set of fastener receivers. As noted above, these stages of placement and preferential assurance are approximately concurrent with the placement and securing stages with respect to the components related to the supply of electric power. Securing the second housing in the first housing, either bottom-up or top-to-bottom, is preferably by clipping the fasteners in the common direction with additional receivers for fastener in the first housing member. While it is highly preferred that the lighting fixture be assembled with its upper and lower members and all its components inverted, and that it is highly preferred that the components, including the components related to the supply of electrical power be secured in the upper member, The manufacturing method, with its fixation in one direction and assembly of components, can be carried out in other ways. For example, the components can be joined to the lower member, which during assembly is on a support structure in its normal orientation (ie, in a non-inverted orientation). In such a case, the bra receptors would be in the lower limb. The preferred embodiment in which the receptacle is lowered into the housing, can be achieved by the use of a U-shaped receptacle mounting member, which has the receptacle between the legs of the U-shaped member. of the components, the upper member is then joined to the lower member. All this fixing process is carried out in one direction. As used herein, the following terms have the meanings given below unless the context otherwise requires: With reference to an industrial ceiling lighting fixture, the term "ceiling" refers to lamp holders that are commonly mounted, either directly or indirectly, in ceilings or roof structural members of some kind such as in factories, warehouses, etc. (without considering the purpose) or in any other roof structure or raised in place for the purpose of supporting a lighting lampholder. The term "industrial" is used in order to make a difference with respect to residential lighting or the like, and none of these terms will be taken as limiting.The term "components related to the supply of electric power" includes reactors, capacitors , ignition electrodes and other devices to create the appropriate electrical energy that can be used for a selected lamp such as high intensity discharge lamps (HID) of different types.The term "substantially enclosed", which is used with respect to a space within a housing, means surrounded, although it does not mean closed of the inflow and outflow of air. Instead, as can be seen in the drawings certain walls of the housing are strongly ventilated so as to allow the inflow and outflow of air essentially without restriction, for cooling purposes. This invention involves enclosing the components related to the electrical power supply and the recess of the receptacle in the housing and for these reasons the cooling by the convection flow is of great importance. As used with respect to the receptacle, the term "substantially inside" does not exclude or eliminate the profusion of a small portion of the lamp receiving end of the receptacle of the housing, through the cutout or receptacle window.
The term 'low profile' that is applied to the lighting fixture means that it is of a lower profile that occurs when the receptacle is not recessed in the housing.The terms "upper" and "lower" are used in this document. with reference to the lampholder, or parts thereof, assume the orientation of normal use of the lampholder. The industrial ceiling lighting lamp of this invention, in its various forms, overcomes certain problems and deficiencies of the prior art, including those referred to below. Breva Description of the Drawings The drawings illustrate the preferred embodiments that include the features and features of the invention noted above. The invention will be understood quickly from the description and drawings, in which: Figure 1 is a perspective view of a preferred industrial lighting lamp holder in accordance with this invention; Figure 2 is an exploded perspective view of the device of Figure 1; Figure 3 is a top perspective view of the upper housing member of the device of Figure 1;
Figure 4 is a bottom perspective view of the upper housing member of the device of Figure 1; Figure 5 is a perspective view of another embodiment of the device of Figure 1; Figure 6 is a perspective view of the housing and the junction box of the device of Figure 5; Figure 7 is a perspective view in partial section of the connection box of Figure 5; Figure 8 is a front elevation of the device of Figure 5; Figure 9 is a rear elevation of the device of Figure 5; Figure 10 is a side elevation of the device of Figure 5 in the suspended position during installation or removal; Figure 11 is a top view of the device of Figure 5; and Figure 12 is an exploded perspective view of the assembly of a device according to this invention illustrating the manufacturing method. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The drawings illustrate a ceiling industrial lighting fixture 20 made with the use of the method of this invention. The lighting lamp holder 20 includes: a housing 22; the components related to the electric power supply including a reactor 24, a capacitor 26 and an ignition electrode 30; a capacitor assembly contact sheet 28; a receptacle assembly 32; a lamp mounting receptacle 34; and a reflector 36. These elements are better seen in Figures 2 and 12. With reference in Figures 1-2 and 12, the housing 22 has the upper and lower members forming the cover 40 and 80, respectively. The upper member 40 forms an upper wall 42, two opposite side walls that extend downwards 44 and two opposite portions of side wall that extend downwards 46. The lower member 80 is in forced clutch with the upper member 40 and forms a lower wall 82 and two opposite upwardly extending side walls 84, which together with the downwardly extending side wall portions 46 and the end walls 44 of the upper member 40, define a substantially enclosed space within the housing 22. The lower member 80 includes the ears 86 at the terminal edge 88 of the side walls 84. The lower wall 82 of the lower member 80 further defines a receptacle window 90. As seen in Figures 3 and 4, the walls of end 44 of upper member 40 terminate at flanges 1
at the end 48 with the lower wall 82 of the lower member 80 by the fasteners 38. The upper member 40 includes a central upper wall portion 50 having the opposite edges 52 and a pair of side upper wall portions 54 below and at the opposite sides of the central upper wall portion 50. Each of the lateral upper wall portions 54 has an inner edge 56 and an outer edge 58. The downwardly extending side wall portions 46 of the upper member 40 include a pair of opposite portions 60 of upper side wall, each of which extends downward from one of the opposite edges 52 of the central upper wall portion 50 toward the inner edge 56 of one of the lateral upper wall portions 54. The lateral upper wall portions 54 they include a flange or side flange 62 at its outer edge 58 and further define the ear receiving openings 64 which are capable of being engaged with the ears 86 of the upwardly extending side walls 84 of the lower member 80. The components related to the electric power supply 24, 26 and 30 the capacitor mounting contact sheet 28, the receptacle 34 and the receptacle assembly 32 are all enclosed within and secured with respect to the upper member 40 of the housing 22. The upper member 40 of the housing 22 provides a plurality of bracket receivers 39 receiving fasteners in a threaded clutch therewith for the purpose of securing to the reactor 24, the capacitor 26, the igniter or ignition electrode 30 and a receptacle assembly 32 in the housing 22. The lamp mounting receptacle 34 is secured in the receptacle assembly 32 and is located with its receiving end of lamp substantially aligned vertically and horizontally with the cutout or window of receptacle 90. With reference to Figures 8 and 9, the lower wall 82 of the lower member 80 further includes a plurality of descendant projections 92 about the receptacle window 90. The reflector 36 is secured in the housing 22 by joining in the descendant projections 92 forming an air flow space between the lower wall 82 and the reflector 36. The housing 22 further includes a plurality of leaks or holes 130 in different positions in the upper member 40 and the lower member 80, in particular, include in the positions adjacent to the components that produce heat, such as reactor 24. As seen in Figures 3 and 4, the central upper wall portion 50 of the upper member 40 has the inner and outer surfaces 66 and 68, respectively, and a central region 70 defining a pair of adjacent openings of suspension member 72 through them. The central upper wall portion 50 further includes the fastener openings 74 on either side of the suspension member openings 72. The suspension member 76, Figures 1 and 2, is formed by a series of portions that include (a) a base portion 76a having a threaded opening 77 therethrough and secured to the inner surface 66 of the central upper wall portion 50 adjacent to an aperture chosen from the suspension member openings 72, (b) a through portion 76b extending through the chosen apertures of suspension member 72, (c) a displacement portion 76c extending from the through portion 76b in the lateral direction along the outer surface and (d) a portion of displacement 76d extending from the displacement portion 76c and forming an upper support end 78. The suspension member 76 can be mounted with its displacement portion 76d in any was one of four positions that is closer to the center of gravity of the lighting lampholder 20 which is determined by the particular choice of the components related to the supply of electrical energy within the housing 22. The base portion 76a of the suspension member 76 is secured to the inner surface 66 of the upper wall 42 with a fastener extending through one of the fastener openings 74 in the upper wall 42 and in a clutch that can be threaded with the threaded opening 77 of the base portion 76a of suspension member 76. Referring now to Figures 5-7 and
11, a junction box 94 can be secured in the housing 22 adjacent to the central region 70 of the upper wall 50. The junction box 94 is generally boxed in shape and includes an upper surface 96, a first and second walls sides 98 and 100, respectively, and opposite end walls 102, upper surface 96 of junction box 94 defines a second pair of adjacent openings of suspension member 104 therethrough, second pair of openings of suspension member 104 is located and arranged so as to provide at least three positions for mounting the suspension member 76. The upper member 40 of the housing 22 further includes a pair of separate hook-holding openings 120 at the common edge of the suspension member. an upper side wall portion 60 and the central region 70 of the upper wall 50. As best seen in Figures 4 and 10, the hook fastening openings 120 are formed The first tab portions 122, which are bent inward from the upper side wall portion 60 adjacent the upper wall 50 and end upwardly at the rotary edges 126, are provided. The junction box 94 includes a pair of hooks 106 protruding from the first side wall 98 thereof. Each of the hooks 106 protrudes in one of the hook-holding openings 120 and upwards around the turning edge 126 in the upper member 40 of the housing 22. By this arrangement, the lighting socket 20 can be hung or suspended safely in the hooks of the junction box 106 during installation or service without being fully secured in the junction box 94. The second tab portions 124 are bent inward from the central region 70 of the adjacent upper wall 50 to the upper side wall portion 60. The orientation of each pair of tab portions 122 and 124, which are at 45 ° with the walls from which they are formed, are such that their distal ends are adjacent, in a close way, with each other. By this arrangement, each pair of tongue portions forms a wiring passage so as to facilitate the organization of the internal wires and protect them from being damaged during assembly. The second edge 100 of the junction box 94 includes an ear 108 protruding downwardly forming a clutch slot for J-shaped fastener 110. A clutch opening for fastener 128 is located opposite the hook fastening openings 120 in FIG. the upper side wall portion 60 of the upper member 40 and receives a fastener 129 in a clutch capable of being threaded therewith in order to secure the junction box 94 in the housing 22, as seen in Figures 5-7. Figure 12 illustrates the manufacturing method of the industrial ceiling lighting fixture 20. Prior to assembly, the upper and lower members 40 and 80 are formed, respectively, preferably, by the operations of stamping and folding a sheet metal. Hereinafter, the assembly involves first placing the upper member 40 in an inverted orientation in a work support structure 132, which may be a table or an assembly line surface. Then, the reactor 24 is placed in its assigned position by attaching the central upper wall portion 50 and is secured in the upper side wall portions 54 with fasteners (not shown) so that they can be screwed with the aligned fastener receivers 39 The capacitor 26 is secured in the upper member 40 between the upper side wall portions 60 by the capacitor mounting contact sheet 28 which is attached to the upper side wall portions 54 in its assigned position, this joint is by means of of fasteners clutched so that they can be threaded with certain of the fastener receivers 39 which are aligned therewith. The ignition electrode 30 is secured in the upper side wall portions 54 by the attachment of fasteners with certain of the aligned receivers for fastener 39. All this attachment is effected by the clutch of fasteners in a common downward direction with certain of the receivers for fastener 39 in the upper side wall portions 54. The receptacle assembly 32 is secured in the upper side wall portions 54 by the attachment of fasteners in the above-mentioned common downward direction with certain of the aligned receivers for fastener 39. The receptacle assembly 32 supports the lamp mounting receptacle 34 within the housing 22. Mounting continues by positioning the lower member 80, in an inverted orientation, on the upper member 40. Next, the lower member 80 is secured in the upper member 40 by means of the fasteners 38 which engage with the receiver for fastener 37. This completes, substantially, the assembly of the lighting lamp holder 20. The reflector 36 can be joined with the lighting lamp holder 20 while preparing the installation at the work site. However, in some cases, the reflector 36 can be immediately attached to the illumination lamp holder 20 based on the termination of the union of the lower member 80 with the upper member 40. If this were done, the reflector 36, in an inverted orientation , would be secured in the downward projections 92 of the lower wall 82 using fasteners capable of being engaged with the fastener receivers 93 formed in the descending projections 92, in the aforementioned common direction. When the assembly is finished, the lighting socket 20 is removed from the work support structure 132 and is ready for packing and shipping. The sheet of metal used for shaping the upper member 40 and the lower member 80 is of a sufficient caliper so as to provide structural integrity although it allows performing the required folding and embossing operations. The components related to the electrical power supply that are acceptable as well as other components used in the manufacture of the lighting lamp holder 20 are known to those skilled in the art. The weights, shapes and sizes of these components, including the reflector, vary greatly and are fully accommodated by the pendant or suspension mounting system described above. The low profile that is made possible by recessing the receptacle 32 in the housing 22 allows the vertical dimension of the housing 22 to be as low as 11.43-15.24 cm (4.5-6 inches), even when using electrical components that are standard in the industrial ceiling lighting fixtures. While the principles of this invention have been described in connection with specific embodiments, it should be clearly understood that these descriptions are made only by way of example and are not intended to limit the scope of the invention. It is noted that in relation to this date the best method known by the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.