WO2017160339A1 - Recessed supporting device for installation of led illuminating devices in walls and ceilings - Google Patents

Abstract

A recessed supporting device is provided for installation of LED illuminating devices comprising a main channel section, shorter open-top end modules securable to a first end of the main channel section, and an elongated lens securable over the top of the main channel section. Flanges extending from the bottom of the main channel section are secured to a wall stud or ceiling joist and end modules are secured to the ends of the main channel section. An LED strip is secured to the bottom inside the main channel section and connected to appropriate wiring through one of the end modules. Drywall is laid to the edges of the device and a channel cap is secured across the top of the end modules and foam inserted into the main channel section., The drywall is spackled and painted. The foam is removed and the lens secured over the main channel section.

Description

RECESSED SUPPORTING DEVICE FOR INSTALLATION OF LED ILLUMINATING

DEVICES IN WALLS AND CEILINGS

RELATED APPLICATION DATA

[0001] The present application claims the benefit of commonly-owned and copending United States Provisional Patent Application Serial Number 62/307,586, entitled RECESSED SUPPORTING DEVICE FOR INSTALLATION OF LED ILLUMINATING DEVICES IN WALLS AND CEILINGS, filed on March 14, 2016, which application is incorporated herein by reference in its entirety. The present application is also related to commonly-owned and co-pending United States Design Application Serial Number 29/557,865, entitled WALL INSTALLATION SUPPORT FOR LED STRIP LIGHTING, filed on March 14, 2016, and to commonly-owned and co-pending International Design Application Serial Number

, entitled WALL INSTALLATION SUPPORT FOR LED STRIP

LIGHTING, filed on the filing date hereof, which applications are incorporated herein by reference in their entireties

FIELD OF THE INVENTION [0002] This invention relates to the field of lighting, and more particularly, the field of in-wall/ceiling installation of LED-based lighting.

BACKGROUND OF THE INVENTION

[0003] There are many kinds of linear lighting apparatuses. Many of the most recent ones consist of light emitting diodes (LEDs) as light sources. LEDs are individual light sources, that, when combined on a flexible strip, can give off a linear "line" of light. This line of light Is desirable in both offices and homes, in vertical and horizontal installations (and any angle in between). [0004] One limitation that exists in the industry today is the lack of a product that is well-designed for recessed flangeless installation, using a remotely installed LED driver, inside drywall, such as 5/8" thick, which is a common thickness of drywall. An advantage of remotely installing an LED driver is that the driver can easily be changed with a driver having the same specifications upon device failure, without the need for removing the entire fixture.

[0005] In order for a product to be considered to be "flangeless" by common standards, it has to contain a thin flange, which allows for the installer to stop the spackle before the lens. Without such a flange, the spackle installation will be messy and won't give the light a seamless look,

[0006] There are a small number of products that do exist today for this kind of installation, but these products do not consider the flow of installation. One product that exists today, illustrated in FIG. 1 , requires that the drywall be cut after installation to allow for a channel 10, LED strip 12, and covering lens 14 to be placed inside. This makes installation difficult, as the drywall 20 needs to be properly marked before the channel is placed. It also requires the electrician and painter/spackler to each return twice to the job site. First, the electrician places the driver and wiring. Then the painter/spackler lays the drywall 20. Then, the electrician returns to place and wire the LED channel 10 and LED strip 12. Then, the painter/spackler needs to return to spackle and paint 22 the drywall 20. This leads to wasted time and can lead to miscommunications between the parties involved. The reason for this installation process is because the front flange 16 is connected to the main channel section 10. Therefore, the only practical way to have the drywall 20 underneath the front flange 16 is to have the drywall 20 installed prior to the channel 10.

[0007] Moreover, heat from the LED strip 12 (represented by the arrows in FIG. 1 ), dissipated through the top flange 16 acting as a heat sink, may cause the paint, spackle, or both to crack, as illustrated in FIG. 1 .

SUMMARY OF THE INVENTION [0008] Embodiments of the present invention provide a recessed supporting device for installation of LED illuminating devices and a method for installing LED illuminating devices. The device comprises a main channel section, shorter open-top end modules securable to first and second ends of the main channel section, and an elongated lens securable over the top of the main channel section. Flanges extending from the bottom of the main channel section are secured to a wall stud or ceiling joist and end modules are secured to the ends of the main channel section. An LED strip is secured to the bottom inside the main channel section and connected to appropriate wiring through one of the end modules. Drywall is laid to the edges of the device and a channel cap is secured across the top of the end modules and foam is temporarily inserted into the main channel section., The drywall is then spackled and painted. The foam is removed and the lens secured over the main channel section.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a schematic view of a prior art LED strip installation;

[0010] Figure 2 is a schematic view of an embodiment of an LED strip installation supporting device of the present invention as installed;

[0011] Figure 3 is an exploded view of an embodiment of the support device of Figure 2;

[0012] Figure 4 is a top perspective view of the support device of Figure 2, with an LED lighting strip positioned thereon;

[0013] Figure 5 is a top view of an embodiment of the support device of FIG. 2;

[0014] Figure 6 is a top view of the support device of Figure 2, with the jagged lines indicating elongation thereof in conformity with the length of LED strip lighting used therewith;

[0015] Figure 7 is a bottom view of the support device of Figure 2; [0016] Figure 8 is a bottom view of the support device of Figure 7, with the jagged lines indicating elongation thereof in conformity with the length of LED strip lighting used therewith;

[0017] Figure 9 is a side view of the support device of Figure 2; [0018] Figure 10 is a cross-sectional view of the support device of Figure 2;

[0019] Figure 1 1 is a top view of an end module for the LED strip support device of Figure;

[0020] Figure 12 is a bottom view of the end module of Figure 1 1 ;

[0021] Figure 13 is a view of one end of the end module of Figure 9; [0022] Figure 14 is a view of the opposite end of the end module of Figure 9;

[0023] Figure 15 is a side view of the end module of Figure 9, with the rear view being a mirror image thereof; and

[0024] Figure 16 is a right side perspective view of the end module of Figure 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0025] The described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

[0026] Embodiments of the device of the present invention provide a recessed apparatus 100 (FIG.2) which allows for the simple installation of LED strip 30 light in, for example, 5/8" drywall 40. The device comprises an aluminum channel 1 10, a lens 102, flanges 120, and end modules 130. The aluminum channel 1 10 acts as a heat sink for the LED strip 30. The lens 102 covers the channel 1 10 and acts to diffuse the light from the LED strip 30. The flanges 120, made from a material such as PVC, act to make an easy flangeless installation using spackle along the sides of the channel 1 10. The end modules 130 are designed to accept a BX or conduit that contains the low-voltage wiring required to power the LED strip 30. The end module 130 is also designed to accept any excess LED strip 30, thereby allowing for the visible portion of the LED strip 30 to be in any length, not just the length set by the LED strip 30 itself. The end modules 130 allow for the flangeless installation of the apparatus 100 on the edges of the channel 1 10.

[0027] Figure 3 is an exploded view of an embodiment of the installation support 100 of the present invention. Specifically, the device 100 includes an elongated open-top main channel section 1 10 and one or two elongated open-top end modules 130. The main channel section 1 10 includes a bottom 1 12, from which a pair of spaced apart sidewalls 1 14 extend perpendicularly upwards, and from which a pair of bottom flanges 1 16 extend outward beyond the sidewalls 1 14 (see also FIG. 4). The bottom 1 12, sidewalls 1 14, and bottom flanges 1 16 are preferably formed as a single unit, as illustrated in the end cross-sectional view of FIG. 10, and preferably formed from aluminum. Grooves 1 18 in the top edges of the sidewalls 1 14 are configured to receive top flanges 120, preferably formed from PVC or other like material, as will be described below. When the top flanges 120 are inserted into the grooves 1 18, the distance between their outer edges is approximately equal to the distance between the outer edges of the bottom flanges 1 16. FIG. 5 is a top view of the main channel section 1 10 with the top flanges 120 installed while FIG. 6 is a similar view with the jagged lines indicating that the main channel section 1 10 is not limited to any particular length but may be formed in a length to accommodate the length of an LED strip light 30. FIGs. 7 and 8 are bottom views of the main channel section 1 10, corresponding to FIGs. 5 and 6, respectively. FIG. 9 is a side view of the main channel section 100 while FIG. 10, as noted above, is an end cross-sectional view of the main channel section 1 10 with the lens 102 installed.

[0028] The end modules 130 are of similar design, though shorter in length.

Specifically, each end module 130 includes a bottom 132, from which a pair of spaced apart sidewalls 134 extend perpendicularly upwards, and a pair of bottom flanges 136 extending outward parallel to the bottom 132 beyond the sidewalls 134. The bottom 132, sidewalls 134, and bottom flanges 136 are preferably formed as a single unit. Grooves 138 in the sidewalls 134 are configured to receive spaced apart flanges extending perpendicularly from the bottom surface of a planar top cap 140, as illustrated in FIG. 16 and as will be described below. When the flanges in top cap 140 is inserted into the grooves 138, the distance between their outer edges is approximately equal to the distance between the outer edges of the bottom flanges 136. An end cap 142 closes the outer end of the end module 130.

[0029] FIG. 10 is a top view of the end module 130 with the channel cap 140 installed FIG. 12 is a bottom view of the end module 130. FIG. 13 is an cross- sectional view of one end of the end module 130 with the channel cap 140 and end cap 142 installed while FIG. 14 is an cross-sectional view of the other end of the end module 130. FIG. 15 is a side view of the end module 130 and FIG. 16 is a perspective view of the assembled end module 130. [0030] Referring back to FIG. 3, the end module 130 is secured to the main channel section 1 10 with a pair of connectors 150.

[0031] To install the installation support device 100, an installer, such as an electrician first takes the main channel section 1 10, positions it at the desired location after the structure has been framed in and before drywall has been installed. In some installations, the installer screws the bottom flanges 1 16 of the main channel section 1 10 into the wall studs or ceiling joists. The installer then connects or inserts the end modules 130 to the main channel section 1 10 using the T-shape connectors 150. The installer wires the device using by feeding a BX or other cable through an attached connector into one of the end modules 130. The installer then lays the LED strip 30 onto the bottom 1 12 of the main channel section

1 10, lays any extra LED strip 30 in the end module 130, and secures the channel cap 140 in the grooves 138 and the end cap 142 in the end of the end module 130.

[0032] The painter/spackler then inserts foam 160 (FIG. 4) inside the space between the sidewalls 1 14 of the main channel section 1 10 to protect the inside of the main channel section 1 10. The painter/spackler may then lay drywall up to the edges of the device 100, and insert the top flanges 120 into the grooves 1 18 in sidewalls 1 14 of the main channel section 1 10. The painter/spackler then screws the flanges 120 and channel cap 140 into the drywall and spackles up to the edge of the main channel section 1 10 and end modules 130. Spackle is then reapplied, as per typical spackle installation, and the drywall with spackle is painted. Once done, the foam 160 is removed from inside the main channel section 1 10 and the lens 102 is secured onto the main channel section 1 10. The installation is completed and the result is a line of light which is flangeless and which can be installed to any length desirable. 3] In contrast with conventional systems in which aluminum with a thermal conductivity of about 237 is used as the front flange (FIG. 1 , #16), the front flange 120 of the system of the present invention may be formed from PVC, which allows the front flange 120 to remain cool, thereby reducing the risk of the paint and spackle cracking from heat changes. 4] The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

Claims

What is claimed is:

A recessed supporting device for installation of LED illuminating devices, prising: an elongated main channel section, comprising: a first bottom configured to retain a length of LED strip; first and second spaced apart sidewalls, each extending perpendicularly from opposite sides of the first bottom and each having a groove in a top edge; a pair of first bottom flanges extending outward from the first bottom beyond the first and second sidewalls; and first and second top flanges, the first top flange insertable into the groove of the first sidewall and extending perpendicularly outward from the first sidewall, and the second top flange insertable into the groove of the second sidewall and extending perpendicularly outward from the second sidewall, whereby when the first and second top flanges are inserted in the grooves of the first and second sidewalls, a distance between outer edges of the first and second top flanges is substantially equal to a distance between outer edges of the first pair of bottom flanges; a first elongated open-top end module, shorter than the main channel section and securable to a first end of the main channel section, the first end module comprising: a second bottom; third and fourth spaced apart sidewalls, each extending perpendicularly from opposite sides of the second bottom and each having a groove in a top edge; a second pair of bottom flanges extending outward from the second bottom beyond the third and fourth sidewalls; and a planar top cap having a width substantially equal to a distance between outer edges of the second pair of bottom flanges, the top cap further having a third pair of spaced apart flanges extending perpendicularly from a bottom surface of the top cap, the third pair of flanges being insertable into the grooves in the top edges of the third and fourth sidewalls; and an elongated lens securable between the first and second sidewalls of the main channel section.

2. The recessed supporting device of claim 1 , further comprising a second elongated open-top end module securable to a second end of the main channel section.

3. The recessed supporting device of claim 1 , wherein the main channel section is formed from aluminum.

4. The recessed supporting device of claim 1 , wherein the main channel section is formed as a single piece.

5. A method of installing LED illuminating devices, comprising: placing an elongated main channel section against a wall stud or ceiling joist, the main channel section having a first bottom and first and second spaced apart sidewalls; securing first bottom flanges to the wall stud or ceiling joist, the first bottom flanges extending outward from a bottom of the main channel section perpendicular to the first and second sidewalls; securing first and second top flanges to top edges of the first and second sidewalls, respectively, the first and second top flanges extending outward perpendicular to the first and second sidewalls; securing a first end of a first end module to a first end of the main channel section, the first end module having a second bottom and third and fourth spaced apart sidewalls; securing an LED strip to the bottom of the main channel section between the first pair of sidewalls; extending an electric cable through the first end module; connecting the electric cable to an end of the LED strip; securing a channel cap across top edges of the third and fourth sidewalls of the first end module, the channel cap extending beyond the third and fourth sidewalls; temporarily inserting foam into the main channel section; laying drywall to the edges of the main channel section and the first end module; painting and spackling the drywall; removing the foam from the main channel section; and securing a lens over the main channel section between the first and second sidewalls.

The method of claim 5, further comprising securing an end cap to a second end of the first end module.

The method of claim 5, further comprising securing a first end of a second end module to a second end of the main channel section.

8. The method of claim 5, further comprising, after securing the LED strip to the bottom of the main channel section, placing any extra length of the LED strip in the second end module.