AU2003250622B8 - A down light protector arrangement - Google Patents

Description

WO 2004/018934 PCT/AU2003/001076 A Down Light Protector Arrangement Field of the Invention 5 The invention relates to a protector arrangement for a down light. Background of the Invention Down lights are generally mounted in an aperture formed in a wall or ceiling. 10 The construction of typical down lights is generally such that dust, insulation, insects and other contaminants are able to pass from the wall or ceiling space through any gap formed between the aperture and the down light. This can result in the down lights becoming dirty and contaminants entering the room. 15 Another problem with down lights is that many are powered via a transformer. Many transformers generate heat which, if not dissipated safely, can be a fire risk. The risk of fire is particularly high in situations where the transformer is in close proximity to or even covered over by insulation or any other material in the wall or ceiling space. For this reason, down light transformers are normally 20 required to be located at least 50 mm away from any insulation, ventilated and 50mm clear of any other material. It is recognised that down lights and transformers are not always simple to install and that in many instances they are not installed properly. Thus they 25 may represent a significant safety risk. It is also recognised that even where a down light transformer is originally installed properly, subsequent improper installation of insulation or movement of the previously installed insulation can result in a fire risk. 30 Another problem associated with down lights is that a significant amount of heat is generated from the down light globe itself. This heat rises in the ceiling space heating any element it contacts. If this heat is not dissipated safely it may result in a fire risk.

-2 The present invention seeks to provide a down light protector arrangement that addresses at least some of the above mentioned problems. Summary of the Invention According to the present invention there is provided a protector arrangement for a 5 down light including componentry, said protector arrangement including housing means arranged to protect and encapsulate the componentry of the down light which extends beyond a surface of a wall or ceiling into a wall space or a ceiling space when the down light is mounted in said wall or ceiling, said housing means being arranged so that in use an isolating gap is maintained between the componentry and 10 an inner surface of the housing means and wherein said housing means includes cable access means arranged so that the housing means can be positioned about said componentry of said down light which was previously installed in said surface without need for disconnection of any electrical cable connected to said componentry, said cable access means being arranged so that the integrity of the encapsulation of 15 the componentry is maintained during use of the protector arrangement. The componentry of the down light extends through an aperture formed in the surface. The housing means is arranged so as to prevent contaminants from contacting the componentry or from passing from the wall or ceiling space through the aperture formed in the surface. 20 The housing means may be arranged to be positioned on the surface or to extend through the aperture formed in the surface. The housing means may also be arranged to be positioned on a portion of the componentry of the down light. In accordance with a first form of the invention, the locating means locates the transformer externally of the housing means and distally of the surface. 25 Preferably, the locating means locates the transformer substantially above or to one side of the componentry of the down light. The locating means locates the transformer to a position clear of any material located on the surface and/or prevents contact of such material with the transformer. Preferably, the housing means includes an enclosure and the locating means. The 30 locating means preferably includes a transformer platform. The WO 2004/018934 PCT/AU2003/001076 -3 transformer platform is arranged to be connected to the enclosure. In one preferred arrangement the transformer platform is arranged to be pivotally connected to the enclosure. 5 The enclosure may also include a base member. The base member may be arranged to be integrally formed with or connected to the enclosure. The transformer platform is preferably arranged so that a cable from the transformer can pass into the enclosure and be connected to the down light 10 componentry. The transformer platform may also include means for positioning a cable extending from the transformer. 15 The transformer platform may also include projecting means arranged to locate the transformer on the transformer platform. The projecting means may also be arranged to elevate the transformer above the transformer platform so as to improve air flow around the transformer. 20 The enclosure and/or the transformer platform may include ventilation means for allowing airflow into and out of the housing means. The ventilation means is preferably formed so as to prevent insects and/or contaminants from passing there through. 25 The enclosure and/or the transformer platform may include access means for allowing access of a cable into the enclosure. The access means may be an opening formed in the enclosure and/or the transformer platform. The opening may be covered by a cover. Alternatively, the access means may be formed as a portion of reduced cross-section of the housing and/or the platform which is 30 arranged so that an aperture can be readily cut or punched there through so as to allow access by the cable.

WO 2004/018934 PCT/AU2003/001076 -4 The base member may include breakaway means. The breakaway means being arranged to be broken away so that different sized and/or shaped apertures can be formed in the base member. The aperture in the base member is preferably formed so as to substantially coincide in size and shape 5 with the aperture formed in the surface to house the down light. A surface protector may also be provided. The surface protector is preferably arranged to line the aperture formed in the surface so as to prevent damage to the wall of the aperture or to the surrounding surface. 10 In accordance with one arrangement of the first form of the invention, the enclosure and base member are integrally formed as a single sheet of flexible material which can be folded to form the desired shape of the housing means. 15 In accordance with a second form of the invention, the locating means locates the transformer internally of the housing means. Preferably, the locating means positions the transformer so that it is not in direct contact with the surface and so that there is spacing between the transformer and the housing means. 20 In accordance with the second form of the invention, the housing means includes a base member and a cover. The locating means may be attached to or integrally formed with the base member. The base member and the cover are preferably arranged to be connected together. 25 In accordance with either form of the invention, the protector arrangement is made from a light weight material. The material is preferably fire retardant and/or non electrically conductive. In accordance with one preferred form of the invention, the protector arrangement is made of a plastics material. The plastics material is preferably U.V stablilised. 30 The protector arrangement is preferably arranged to be secured to the surface. To this end, the base member and/or the enclosure may be secured to the surface with screws or pins or the like.

Description of the Drawings Embodiments of the invention will now be described, by way of example only, with 5 reference to the accompanying drawings in which: WO 2004/018934 PCT/AU2003/001076 -6 Figure 1 is an assembly view of a protector arrangement in accordance with an embodiment of the first form of the invention; 5 Figure 2 is a detailed view of the platform shown in Figure 1; Figure 3 is a front side perspective view of the protector arrangement shown in Figure 1; 10 Figure 4 is a rear side perspective view of the protector arrangement shown in Figure 1; Figure 5 is a cross sectional view of the protector arrangement shown in Figure 1 in situ; 15 Figure 6A is a first perspective view of the protector arrangement shown in Figure 1 with half of the housing removed; Figure 6B is a second perspective view of the protector arrangement shown in 20 Figure 1 with half of the housing removed; Figure 7 is an assembly view of a protector arrangement in accordance with another embodiment of the first form of the invention; 25 Figure 8 is a front side perspective view of the protector arrangement shown in Figure 7; Figure 9 is a cross sectional view of the protector arrangement shown in Figure 7 in situ; 30 Figure 10 is a perspective view of the enclosure of the protector arrangement shown in Figure 7; -7 Figure 11 is a perspective view of the enclosure shown in Figure 10 in a folded configuration; 5 Figure 12 is a top view of the enclosure shown in Figure 11; Figure 13 is an assembly view of another protector arrangement; Figure 14 is a front side perspective view of the protector arrangement shown in 10 Figure 13; Figure 15 is a cross sectional view of the protector arrangement shown in Figure 13 in situ; 15 Figure 16 is a perspective of the enclosure shown in Figure 13; Figure 17 is a rear view of the enclosure shown in Figure 13; Figure 18 is an assembly view of another protector arrangement; 20 Figure 19 is a front side perspective view of the protector arrangement shown in Figure 18; Figure 20 is an underneath view of the cover shown in Figure 18; 25 Figure 21 is a perspective view of the base member shown in Figure 18; Figure 22 is an assembly view of another protector arrangement; 30 Figure 23 is an underneath view of the cover shown in Figure 22; -8 Figure 24 is an assembly view of another protector arrangement; Figure 25 is an underneath view of the cover shown in Figure 24; 5 Figure 25A is a perspective view of another protector arrangement; Figure 25B is a perspective view of another protector arrangement; Figure 26 is an assembly view of a protector arrangement in accordance with another 10 embodiment of the first form of the invention; Figure 26A is an assembly view of a modified form of the protector arrangement shown in Figure 26; 15 Figure 27 is an assembly view of a protector arrangement in accordance with another embodiment of the invention; Figure 28 is a perspective view of the protector arrangement shown in Figure 27 with a transformer in the transformer house; 20 Figure 29 is a perspective view of the transformer house shown in Figure 28; Figure 30 is a perspective view of the protector arrangement shown in Figure 27 with the enclosure in an open condition; 25 Figure 31 is a cross sectional view of the protector arrangement shown in Figure 27 with a down light and transformer installed; Figure 32 is an assembly view of a protector arrangement in accordance with an 30 embodiment of the first form of the invention; WO 2004/018934 PCT/AU2003/001076 -9 Figure 33 is a cross sectional view of the connection between the enclosure and the transformer house shown in Figure 32; 5 Figure 34 is a top view of the protector arrangement shown in Figure 32; Figure 35 is a cut away view of the protector arrangement shown in Figure 32 installed about a down light; 10 Figure 36 illustrates an alternative form of the ceiling protector; Figures 37A and 37B illustrate another alternative form of the ceiling protector; Figures 38A and 38B illustrate another alternative form of the ceiling protector; 15 Figure 39 illustrates another alternative form of the ceiling protector; Figure 40 illustrates half of a modified base for use with protector arrangements in accordance with the first form of the invention; and 20 Figure 41 illustrates a half of another modified base for use with protector arrangements in accordance with the first form of the invention. Detailed Description of the Preferred Embodiments 25 Figure 1 illustrates a protector arrangement 10 in accordance with a first embodiment of the invention. The protector arrangement 10 includes a housing means in the form of an enclosure 12. The enclosure 12 includes a base 14 and a transformer locating means 16. The locating means 16 is formed as a removable transformer platform 16. As best illustrated in Figures 3 and 4, the 30 platform 16 is arranged to seat a transformer 18 that is associated with a down light 20.

WO 2004/018934 PCT/AU2003/001076 - 10 The down light 20 is mounted within an aperture 22 formed in a ceiling 26. An upper part of the down light 20 extends beyond the upper surface of the ceiling 26. The upper part of the down light 20 includes componentry such as a globe shield 20a, a down light globe 20b and a pair of spring clips 20c. As will be 5 described in more detail below, the enclosure 12 is arranged to be located on ceiling 26 so that it encloses the componentry of the down light 20. The enclosure 12 is box-shaped and is formed in two halves that are arranged for connection together. The halves of the enclosure 12 are connected together 10 along opposed vertical joints by means of complimentary male and female connectors 25. Following location of the two halves of the enclosure 12 about the down light's componentry, the connectors 25 along the two opposed vertical joints can be connected together. The installation process of the protector arrangement 10 about a down light 20 will be described in more detail 15 subsequently. Found on the inside of each half of the enclosure 12 is a finger ledge 15. The function of the finger ledge 15 will be described subsequently. 20 The base 14 is formed as two symmetrical halves which, when assembled together, define a central aperture 27. The aperture 27 is sized so as to be substantially the same size as the aperture formed in the ceiling 26 into which the down light 20 is to be installed. To enable the size of the aperture 27 to be varied, the base 14 includes a plurality of removable segments 28 that are 25 arranged to be snapped from the base 14 so as to increase the size of the aperture 27. The segments 28 are shown as ring shaped. However, the segments may adopt other shapes such as square, hexagonal or octagonal etc. The base 14 is arranged to snap fit to the lower part of the enclosure 12. This 30 snap fit connection is achieved in the illustrated embodiment by virtue of a plurality of fingers 30 which extend from the base 14 and which are arranged to be received within complimentary shaped apertures 32 formed in the lower part of the enclosure 12.

WO 2004/018934 PCT/AU2003/001076 - 11 The transformer platform 16 is substantially U-shaped and is arranged to be mounted on a seat formed in an upper part of the enclosure 12. As best shown in Figure 6A, the platform 16 includes a main body 16a and a pair of side wings 5 16b. The side wings 16b of the platform 16 are arranged to be located under transformer restraint lugs 12c formed in the upper part of the enclosure 12. The wings 16b preferably include a plurality of perforations 16c for ventilation purposes. 10 The transformer platform 16 also includes a platform catch 34 and a finger handle 36 which both extend from beneath the main body 16a. The platform catch 34 and handle 36 are arranged at a first end of the main body 16a so that a first edge portion 12a or the second edge portion 12b of the upper part of the enclosure 12 can be located there between. This enables the platform 16 to be 15 hung from the first edge portion 12a or second edge portion 12b during the installation process and to be subsequently pivoted upwardly for location on the seat formed in the upper part of the enclosure 12. The main body 16a of the platform 16 has a second end which is arranged to 20 rest on the respective opposite edge portion 12a, 12b of the upper part of the enclosure 12 when the platform is located in the seat formed in the enclosure 12. It will also be appreciated that the platform 16 can be pivoted in an upward direction away from the base 14 when holding the handle 34 from inside the enclosure 12 and pressing upwardly. 25 Formed on the main body 16a of the platform 16 are a series of ribs 16d. These ribs 16d, together with locating lugs 16e, locate the transformer 18 in the proper position on the platform 16 and also strengthen the platform 16. The ribs 16d and lugs 16e also serve to lift the transformer 18 slightly above the main 30 body 16a of the platform 16 so as to enable better air flow around the transformer 18. This aids to dissipate heat generated by the transformer 18 and the down light globe 20b.

WO 2004/018934 PCT/AU2003/001076 - 12 The platform 16 includes a handle 38 which extends longitudinally of the main body 16a of the platform 16. The handle 38 includes a cable tag 40 which is arranged to receive a mains power cable 42 from the transformer 18. The cable tag 40 is also configured so as to securely locate the cable 42 against the 5 protector arrangement 10 when the transformer 18 is installed on the platform 16. This will be described in more detail subsequently. The protector arrangement 10 shown in Figure 1 also includes a ceiling protector 50. The ceiling protector 50 may be formed as either a split ring or a 10 complete ring which is arranged to be located within the aperture 22 formed within the ceiling 26. Various different forms of ceiling protectors 50 are illustrated in Figures 36 to 39. The ceiling protector 50 as shown in Figure 1 includes an upper peripheral ring 15 of tongues 52 and a lower peripheral ring of tongues 54. The tongues 52 and 54 are arranged so that when the protector 50 is located within the aperture 22, the lower tongues 54 are positioned against the underside of the base 14 and the upper tongues 52 are positioned on top of the base 14. The positioning of the upper tongues 52 of the protector 50 when it is located within the aperture 20 22 in the ceiling 26 is best depicted in Figure 6B. It will be appreciated by those skilled in the art that the ceiling protector 50 may not always be required. The enclosure 12 includes a plurality of perforations/apertures/holes 12d which are positioned to assist ventilation of the down light 20. The perforations 12d 25 are arranged so as to prevent access by insects and other contaminants. The perforations 12d are also preferably arranged in a semi vertical/ vertical surface of the enclosure 12 so as to prevent dust or the like from clogging the perforations 12d and thereby decreasing their ability to ventilate. 30 Figure 5 illustrates the protector arrangement 10 mounted about the down light 20. This figure illustrates the connection of the low voltage cable 44 to the down light 20. The low voltage cable 44 passes between a covered cable access 44a formed in the platform 16 and the upper edge portion 12a of the WO 2004/018934 PCT/AU2003/001076 - 13 enclosure 12. The covered cable access 44a is shielded by the platform 16 as best possible to prevent insect entry there through. The covered cable access 44a is also positioned to locate the cable 44 as far as feasibly possible away from any heat produced by the transformer 18. 5 The protector arrangement 10 is installed about a new down light 20 in a ceiling in accordance with the following general instructions: 1. Pre-wire the mains power wiring for the down light 20 in accordance with 10 the manufacturer's instructions; 2. Snap off the ring segments 28 from each half of the base 14 so that the aperture 27 formed in the base 14 is sized to suit the down light 20 to be installed. Install the base halves 14 in their respective enclosure halves 12; 15 3. Whilst in the ceiling space, assemble the two halves of the enclosure 12. Fit a ceiling protector 50 if required. Hang the transformer platform 16 from the first edge portion 12a of the enclosure 12. Lay the protector arrangement 10 on its side and pass the mains cable through the top of the protector arrangement 20 10 and through the base 14 to within reach of the position in which the aperture in the ceiling 26 is to be cut; 4. Cut the aperture in the ceiling 26 from below the ceiling space; 25 5. Working through the aperture cut in the ceiling 26, locate the protector arrangement 10 in position over the aperture formed in the ceiling 26. Pull the mains power cable 42 down through the aperture to just below the ceiling 26 and connect up the terminals of the transformer 18. Press the mains power cable 42 into the cable tag 40 on the top end of the handle 38. Then complete 30 the transformer installation in one of the following ways to suit the transformer type: a) Two cables on one end of the transformer.

WO 2004/018934 PCT/AU2003/001076 - 14 Bend the transformer's 12 volt cable sharply to run down the transformer 18 and whilst holding them, lift the other end of the transformer 18 and feed the mains power cable 42 and transformer 18 up to a point above the platform handle 38. 5 Slide the 12 volt cables down behind the side of the transformer platform 16. If the transformer 18 is heavy and/or large, manoeuvre the cable free end back so as to rest it in the opposite side 12a of the enclosure 12. Feed the 12 volt cables into their position and push the transformer platform 16 10 upwardly. Complete this movement with a finger on the finger ledge 15 so as to anchor the enclosure 12 whilst the transformer platform 16 is being pushed up and located in the seat in the upper part of the enclosure 12. Carefully pull the 12 volt cable through the enclosure 12 so it can plug into the 15 globe 20b in the down light 20 from below the ceiling 26. Ensure that the transformer platform 16 is properly located in the seat so as to seal against the entry of contaminants. Complete the down light installation in accordance with the manufacturer's instructions. 20 b) One cable at both ends of the transformer. With one hand under the 12 volt cable end of the transformer 18 carefully feed the mains cable and transformer 18 up above the platform handle 38 and then far enough across to be able to slide the 12 volt cable end of the transformer 18 25 back to lie in the seat in the enclosure 12 with the 12 volt cables on the cable access side of the platform 16. Retain the 12 volt leads in hand and pick up the platform 16 and guide the 12 volt leads into position. Lift the platform 16 with a finger on the finger ledge 15 30 to anchor the enclosure 12 in position whilst the platform 16 is being pushed up and located in the seat in the upper end of the enclosure 12.

WO 2004/018934 PCT/AU2003/001076 -15 Carefully pull through the minimum required length of 12 volt cable to enable it to plug into the down light globe 20b from below the ceiling 26. Ensure that the platform 16 seals against insect entry and complete the down light installation according to the manufacturer's instructions. 5 The installation process is slightly different where the protector arrangement 10 is installed around existing down lights. In order to install the protector arrangement 10 around existing down lights 20 insulation or the like must first be moved away from the componentry of the down light 20. The two 10 assembled halves of the enclosure 12 and their related bases 14 are located about each side of the componentry of the down light 20 which extends into the ceiling space. The two halves of the enclosure 12 are then pulled together taking care to lift any wire clips sprung onto the ceiling 26 onto the base 14. Connect the vertical joint at the side opposite to where cable entry is required 15 and leave the other vertical joint slightly opened. Place the platform 16 in position and locate the transformer 18 as follows. a) Two cables one end of the transformer. 20 The platform handle 38 and cable tag 40 protrude out from the open vertical joint of the enclosure 12. Accordingly, slide the transformer 18 onto the platform 16, cable free end first and hold the enclosure 12 together at the upper point. The 12 volt cables are fed into the covered cable access covered cable access 44a and the vertical joint of the enclosure 12 is snap-fit together. The 25 mains power cable 42 is fed into the cable tag 40. b) One cable at both ends of the transformer. The platform handle 38 and cable tag 40 protrude from the closed vertical joint 30 of the enclosure 12. The transformer main power cable 42 is placed over the cable tag 40 and the transformer 18 is slid from the open end under the transformer restraint lugs 16e and down the platform 16 until it is centrally positioned. The 12 volt cables are then fed through the open vertical joint into WO 2004/018934 PCT/AU2003/001076 - 16 the covered cable access 44a on the edge of the platform 16. The mains power cable 42 is pressed into the cable tag 40 out of the way. The enclosure 12 is then properly closed about the down light 20. Ensure that the cables and the platform 16 are located correctly with no large gaps for insect or other 5 contaminant entry. Reinstall insulation around the protector arrangement 10 to ensure optimum safe insulation coverage. 10 It will be apparent to people skilled in the art that the installation process described above will be modified in accordance with the conditions found by the installer. Variations in the installation process will be required depending on whether the protector arrangement 10 is to be installed from above or below the ceiling space, whether the protector arrangement is to be installed about a new 15 or an existing down light and the nature of the transformer used etc. The installation processes described above will also need to be varied to suit the various protector arrangements described below. Figure 7 illustrates a protector arrangement 100 in accordance with a second 20 embodiment of the invention. The protector arrangement 100 includes an enclosure 112 and a platform 116. The platform 116 is substantially identical to the platform 16 described previously but may be made of a more flexible or thinner material. The platform 116 is arranged to be attached to the enclosure 112 in a manner similar to that described in relation to the protector 25 arrangement 10 shown in Figure 1. The attachment of the platform 116 to the enclosure 112 is best illustrated in Figure 5. The enclosure 112 is formed from a single piece of resiliently flexible material which can be folded in the manner illustrated in Figures 10 to 12 in order to form 30 the enclosure 112 (Alternatively, the enclosure 112 may be made from two pieces of material). As best illustrated in Figures 10 and 11, the enclosure 112 includes an integrally formed base 114. The base 114 is integrally formed with the enclosure 112 and includes an upright edge flange 114a to assist in WO 2004/018934 PCT/AU2003/001076 - 17 squaring the enclosure 112 during installation. The edge flange 114a also improves the seal between the base 114 and the enclosure 112 to prevent ingress of dust or insects. The base 114 includes location notches 114b to assist in the proper assembly of the parts which make up the base 114. When 5 the enclosure 112 is opened as shown in Figure 10, the base 114 defines an aperture 124 arranged to substantially align with the aperture formed in the ceiling 126 into which the down light 120 is to be attached. Formed on the inner walls of the enclosure 112 is a pair of finger ledges 115. 10 The finger ledges 115 are of assistance during the installation process in the same manner as that described previously in relation to the finger ledges 15. The protector arrangement 100 may be installed either from above or below the ceiling. To install the protector arrangement 100 from below, the protector 15 arrangement is folded into the arrangement shown in Figure 12. The mains power wiring for the down light 20 is passed through the aperture cut in the ceiling 126 and fed through the collapsed enclosure 112 which is then passed through the aperture formed in the ceiling 126. When it is passed through the aperture, the enclosure 112 is released so that it folds out into the arrangement 20 shown in Figure 10. Some manipulation of the enclosure 112 may be required in order to form it into the arrangement shown in Figure 10. The flexible transformer platform 116 is then reduced in size by squeezing the wings 116b inwardly. The platform 116 is then pushed through the aperture and up through the enclosure 112 so as to locate it on the upper part of the enclosure 112. 25 The base 114 is arranged so that when the enclosure 112 is placed on the ceiling 126 abut the aperture the two halves of the base 114 close together. The platform 116 is hung vertically within the enclosure 112 and is retained in 30 this position by a pair of platform locaters 16f (Figure 2) engaging with the wall portions of the enclosure 112 which form the seat. The protector arrangement 100 and the down light are then installed substantially as previously described -18 in relation to the protector arrangement 10. When the platform 116 is in place horizontally on the enclosure 112, the enclosure 112 becomes square and rigid. The ceiling protector 150 is different to the ceiling protector 50 previously described. The tongues 152,154 shown in Figure 7 are advantageous because the tongues 152 5 are arranged to locate within the apertures formed in the segments 28 of the base 14. This serves to better locate the ceiling protector 150 and to hold the two halves of the base 14 together more firmly when the enclosure 112 is of the more flexible type. Figure 13 illustrates a protector arrangement 200. The protector arrangement 200 is different to the previously described protector arrangements 10,100 in that instead of 10 resting upon the ceiling 26 in which the down light is to be installed, the protector arrangement 200 is seated on the down light 20 itself. The positioning of the protector arrangement 200 on the down light 20 is best illustrated in Figure 15. The protector arrangement 200 includes a base member 210 and a transformer support 212. The base member 210 is formed as a substantially tubular shaped 15 member that is configured so that it seats on the down light's flange 20g. The base member 210, when positioned on the flange 20g, is located between the ribs 20f of the down light 20 and the mount 20c for the down light spring clip 20d. The base member 210 includes an aperture 210b arranged so that the power leads from the transformer 218 can be passed there through and be attached to the 20 attachment pin 20e of the down light 20. The base member 210 also includes a pair of catch grids 210c. These catch grids 210c are each arranged to engage with an inside portion of one of the down light spring clips 20d. Apertures 210d in the base member 210 are provided to fit over the mounts of the spring clips 20c. The base member 210 also includes a plurality of base flanges 210e 25 extending there from. The base flanges 21 0e increase the -19 stability of the base member 210 when it is installed and also provide a point for adhesive fixing of the base member 210 to the down light flange 20g. The transformer support 212 is arranged to be connected to the upper edge 210a of the base member 210. As illustrated in this embodiment, the connection between the 5 transformer support 212 and the base member 210 is a "snap fit" connection. The transformer support 212 includes an angled platform 212a and a support base 212b that is arranged to receive the transformer 218. A plurality of ribs 216 extends along the platform 212a so as to elevate the transformer 218 from the platform 212a. This enables better air flow around the transformer 218 so as to help dissipate heat 10 generated by the transformer 218 and the down light 20. A plurality of ventilation perforations 222 are formed in the transformer support 212. These fine ventilation perforations 222 prevent access of insects or other contaminants. The ventilation perforations 222 enable air flow from the inside of the protector arrangement 200 so as to enable heat generated by the down light 20 to be 15 better dissipated. Figure 18 illustrates another protector arrangement 300. The protector arrangement 300 is different to the previously described protector arrangements 10, 100, 200 in that the transformer 318 is located inside the protector arrangement 300 rather than externally thereof. 20 The protector arrangement 300 includes a base 310 and a cover 312. The base 310 includes a base member 311 having an aperture 312 which, when the protector arrangement 300 is in use, is located in alignment with the aperture formed in the ceiling 314 to house the down light 320. The aperture 312 is of substantially the same dimension as the aperture formed in the ceiling 314.

WO 2004/018934 PCT/AU2003/001076 - 20 The base member 311 also includes a transformer stand 316 and a down light shield 325. The transformer stand 316 is arranged so that a transformer 318 can be positioned therein. The positioning of the transformer 318 within the transformer stand 316 is best illustrated in Figure 21. 5 The base 310 and cover 312 are arranged so that an air passage 330 is formed between the transformer stand 316 and the down light shield 325. The air passage 330 acts as a barrier between the transformer 318 and the down light 320. This barrier is effective to prevent heat transfer between the transformer 10 318 and the down light 320. Air flow through the passage 330 also facilitates dissipation of any heat generated by the transformer of the down light globe. Integrally formed with the transformer stand 316 is a plurality of ribs 316a. The ribs 316a serve to elevate the transformer 318 above the transformer stand 316 15 and thus enable air flow around the transformer 318. The transformer stand 316 may also include a plurality of ventilation perforations adjacent the bottom of the transformer 318. Such ventilation perforations assist ventilation of the transformer 318. 20 The base 310 as illustrated is formed in a single piece. However, to enable installation of the protector arrangement about a pre-existing down light 20, the base 310 may be formed in two pieces. For example, the base member 311 could be split along the centre line of the aperture 312 so as to enable the pieces of the base member 311 to be retrofit about a pre-existing down light 20 25 without disconnecting any of the wiring there to. The base 310 may alternatively include a plurality of segments that are arranged to be snapped from the base 310 so as to enable the size of the aperture 312 to be varied. 30 The cover 312 is arranged to fit over the base 310 and may include a handle 312a to enable easy removal from the base 310. Ventilation perforations 312b are located in the cover 312 to aid ventilation of the protector arrangement 300.

-21 The perforations 312b prevent insects or other contaminants from entering the protector arrangement 300. As best illustrated in Figure 21, the base member 310 is held in position on the ceiling 5 314 by the wire spring clips 320a of the down light 320. Alternatively, or in addition, the base member 310 may be attached to the ceiling 314 by screws, pins or the like. Figure 22 illustrates another protector arrangement 400. The protector arrangement 400 is similar to the protector arrangement 300 previously described. The protector arrangement 400 includes a base 410 and a cover 420. The base 410 includes a 10 cupped shaped base member 410a having a central aperture 410b. The aperture 410b is arranged to be positioned over the aperture cut in the ceiling 414 to house the down light 20. The cup shaped base member 410a has inclined walls against which the spring clips 20c of the down light 20 engage when the down light 20 is installed in the aperture formed in the ceiling 26. The "cup" shape of the base member 410a 15 increases insulation coverage to the ceiling closer to the down light aperture and enables 3600 rotation of the down light's spring clips 20c. The base 410 also includes a transformer support 416. The transformer support 416 is arranged to substantially enclose the sides of the transformer 418. The transformer support 416 is arranged so that there is sufficient air flow above the transformer 418 20 to allow dissipation of any heat. Fine ventilations may be provided in the transformer support 416 to aid in the ventilation of the transformer 418. Figures 24 and 25 illustrate a protector arrangement 500 that is a variation of the previously described protector arrangement 400. As is evident from Figure 24, the base member 510 of the protector arrangement is identical to the base member 410. 25 The cover 520 adopts a different configuration to the cover 410 in WO 2004/018934 PCT/AU2003/001076 - 22 that it isolates the transformer 18 and the down light 20 so that they are effectively contained in different enclosures. It is envisaged that the base member 510 may be hinged along a line between 5 the cup shaped base member 510a and the transformer support 516. The cover 520 may be hinged along a corresponding line HL. Such a hinged form of base member 510 and cover 520 is illustrated in Figure 25A. This hinged arrangement of the base member 510 and the cover 520 facilitates access to the transformer support 516 from below the ceiling 22. 10 An alternative hinge arrangement of the base member 510 and the cover 520 is illustrated in Figure 25B. The hinging occurs at both ends of the base member 510 and there is a break between the two cover parts. The base member 510 may be made from a number of different pieces to facilitate retro fit attachment 15 about a down light without need of any wiring disconnection. Figure 26 illustrates a protector arrangement 600 in accordance with a further embodiment of the invention. The protector arrangement 600 includes an enclosure 612 that is similar to the enclosure 12 except that it does not include 20 a seat to house the transformer platform 16. The protector arrangement 600 is for use with a down light 20 which either does not require a transformer or which receives power from a transformer 18 mounted at another location. The protector arrangement 600 is formed as two halves that are connected 25 together along opposed vertical joints by means of complimentary male and female connectors. Alternatively, the two halves may be connected by means of a flexible hinge. A base 614 may be connected to the enclosure 612. Alternatively, the base may be integrally formed with the enclosure 612. 30 The protector arrangement 600 is advantageous because: a) the two halves of the enclosure 612 are readily stackable even when the base 614 is attached; WO 2004/018934 PCT/AU2003/001076 - 23 b) it can be readily attached to an existing down light without disconnecting any of the electrical wiring because the halves of the enclosure 612 can be located around an existing down light; c) it can be used in conjunction with a ceiling protector or a base ( for 5 example see Figure 41, base 14"); d) it can be ventilated at the base with a plurality of ventilation perforations; and e) it can be coupled with a transformer house 860 (described below) to form a twin type housing to suit down light installations with a transformer. 10 Figure 26A illustrates a modified form of the protector arrangement 600 shown in Figure 26. The protector arrangement 600' includes an enclosure 612' formed as two substantially identical halves that are connected together by a connector member 613'. The connecting member 613' adopts the form a a 15 hinge which tends to close the two halves of the enclosure 612' together. Access by cable to the inside of the enclosure 612' is by means of an access hole 617' formed in one or both halves of the enclosure 612'. The enclosure 612' may include "plug and hole" arrangements to enable cable access into the 20 enclosure simply by trimming off the plug on the opposite half of the enclosure 612'. Figures 27 to 31 illustrate a protector arrangement 700 in accordance with another embodiment of the invention. The protector arrangement 700 is similar 25 to the protector arrangement 600 shown in Figure 24. However, the protector arrangement 700 includes a transformer house 760 in which a transformer 718 may be positioned. The protector arrangement 700 includes an enclosure 712 that is formed in two 30 halves and is arranged to be connected together along a rear side by means of a hinge member 713. The hinge member 713 connects the two halves of the enclosure 712 in a manner whereby they hinge outwardly. This "hinge" action is WO 2004/018934 PCT/AU2003/001076 - 24 best illustrated in Figure 30. The hinge member 713 is designed so that it tends to close the two halves of the enclosure 712 inwardly. The transformer house 760 is arranged in this embodiment to be connected by 5 screws 715 to the two halves of the enclosure 712. The transformer house 760 is arranged to receive a transformer 718 there within. When the transformer 718 is small it may be located within the transformer house 760 so that it does not protrude there from. However, for larger sized transformers 718, a break out portion 760a of the transformer house 760 may be detached. This enables 10 an end of the transformer 718 to protrude from the transformer house 760. Figure 28 illustrates the use of the transformer house 760 in this fashion. As shown, the transformer house 760 includes a number of perforations to enable proper ventilation of the transformer 718. 15 As illustrated in Figure 27, the protector arrangement 700 may include a base 714 similar to the base 14 previously described. The protector arrangement 700 may also include a ceiling protector flange 750 similar to the protector flange 50 previously described. The transformer house 760 may include and 20 integral base or a separate base which is arranged for connection thereto. Figure 32 illustrates a protector arrangement 800 similar to the protector arrangement 700 (Figures 27 to 30) in that the transformer 818 is located in a separate transformer house 860. However, in accordance with this 25 embodiment, the down light 20 is located in an enclosure 812 similar to the protector arrangement shown in Figure 26A and the transformer house 860 is a distinct housing which is connected to the enclosure 812. The two halves of the enclosure 812 are connected together along one side by 30 a connector member 813 and on the other side to the transformer house 860 by means of a pair of connector strips 816. The other side of the two halves of the transformer house 860 are connected by means of another connector member WO 2004/018934 PCT/AU2003/001076 - 25 813. The connection of the enclosure 812 to the transformer house 860 is best illustrated in Figure 33. The connector member 813 joins the two halves of the enclosure 812 together 5 and also acts as a return spring so as to bias the two halves of the enclosure 812 to a closed position. The configuration of the connector member 813 is best illustrated in Figure 34. The transformer house 860 includes an integral base. However, it will be 10 appreciated that the base may include a separate component arranged to be connected to the transformer house 860. Such a separate base may be formed in two halves and include snap off rings similar to the base 14 described previously. The inside edge of the base may be notched so as to enable a spacer to be used to hold the transformer house 860 in an open position if 15 required. It will be appreciated by those skilled in the art that the transformer house 860 could be used to protect other forms of sensitive equipment (e.g. speakers). 20 Figure 34 also illustrates how the enclosure 812 and the transformer house 860 can move relative to one another because of the use of the connector strips 816 and the connector member 813. Figure 35 is a cut away view showing the protector arrangement 800 installed 25 about a down light 20. In an alternative arrangement of the protector arrangement 800 (not illustrated), the enclosure 812 and the transformer house 860 may be formed together, rather than being connected by a pair of connector strips 816. 30 Figures 36 to 39 illustrate various modified forms of the previously described ceiling protector 50 arranged in use to protect the aperture in the ceiling 22 which houses the down light 20.

WO 2004/018934 PCT/AU2003/001076 - 26 Figure 36 illustrates a protector arrangement 50' in the form of a flanged ring. In an alternative form, the ring may be split to enable it to be installed from below the ceiling and to fit within different sized apertures in the ceiling 22. 5 Figures 37A and 37B illustrate a protector 50" in the form of a split barbed ring. The barbs 50a" of the protector 50" are arranged to engage in the ceiling 22 as shown in Figure 37B. 10 Figures 38A and 38B illustrate a protector 50' in the form of a ring A which is arranged to be fixed in the aperture in the ceiling 22 by means of a plurality of c shaped spring clips B. Figures 40 and 41 illustrate halves of a modified form of the base. The half 15 base 14' shown in Figure 40 includes segments which can be snapped out to accommodate different sized apertures in the ceiling. The half base 14" shown in Figure 41 includes a lip 14"a that acts as a protector for the wall of the aperture formed in the ceiling 26. The use of this type of 20 base" negates the need to also use a separate ceiling protector 50. It may be formed in quarters on a hinged integral base. Alternatively, the protector 50"" may adopt the form of a threaded ring C arranged to engage with another threaded ring D. Such a protector 25 arrangement is illustrated in Figure 39. Protector arrangements according to embodiments of the invention can be made from many different materials. It is envisaged that the materials would preferably be light in weight, u.v. stabilised, opaque or solid in colour. A clear 30 finish may be used to advantage if the transformer is protected from radiant heat as it will greatly assist in heat dispersion.

WO 2004/018934 PCT/AU2003/001076 - 27 The protector arrangements described above include perforations/apertures to improve the airflow about the down light and/or the transformer. It will be appreciated that some embodiments of the invention may not include such perforations/apertures. It will also be appreciated that the form of such 5 perforations/apertures when included may vary. From the above description it will be apparent that the protector arrangements previously described are all arranged so as to shield the componentry of the down light which extends beyond the surface in which the down light is 10 mounted. In accordance with the first form of the invention, the componentry is shielded by the enclosure. The enclosure is arranged to prevent any material or other items in the wall or ceiling space from contacting the componentry. In accordance with the second form of the invention, the cover that is connected to the base member shields the componentry. 15 Many of the previously described protector arrangements are also arranged to locate the transformer so that it is protected from direct contact with material on the surface. Such protector arrangements are arranged to protect the transformer from contact with such material even if there is movement of the 20 material after installation of the protector arrangement. This is achieved in a variety of different ways. In accordance with some of the embodiments, the protector arrangement includes a transformer platform that locates the transformer externally of the enclosure and above the surface. 25 In other embodiments, the protector arrangement includes a transformer housing arranged to house the transformer externally of the enclosure and to one side thereof. The transformer housing prevents the transformer from coming into contact with any material on the surface. In accordance with an alternate arrangement, the transformer housing includes an aperture through 30 which an upper part of the transformer may extend. The upper part of the transformer is located clear of any material located on the surface.

WO 2004/018934 PCT/AU2003/001076 - 28 In accordance with other embodiments of the invention, the protector arrangement houses the transformer internally of a housing means. In this way the transformer is prevented from coming into direct contact with any material on the surface. 5 The previously described embodiments are all arranged so that there is sufficient clearance around the transformer to ensure that any heat generated by the transformer can dissipate to atmosphere without causing a fire risk. To help the dissipation of such heat the protector arrangements may include 10 ventilation holes/apertures/perforations in the pArts thereof. Such holes/apertures/perforations are preferably arranged so that insects or other contaminants cannot enter there through. Embodiments of the invention are also preferably arranged so that 15 contaminants within the wall or ceiling space cannot enter the housing means and then pass through the aperture in the surface which houses the down light. Embodiments of the invention are also arranged so that any heat generated by the down light globe can safely dissipate to atmosphere without risk of fire. This 20 is typically achieved by providing adequate free space about the down light globe. Embodiments of the invention are relatively simple to install with new down light or to existing down lights. Some of the embodiments can be installed from 25 below the ceiling. This may make the installation process easier, more comfortable for the installer and/or possible in situations where access above the ceiling is limited. The described protector arrangements are light in weight and require minimal 30 room in the wall or ceiling space. They are also relatively cheap to manufacture and thus will not greatly increase overall product and installation costs.

WO 2004/018934 PCT/AU2003/001076 - 29 Protector arrangements according to the invention ensure that the down light remains clean. They also enable the down light and any transformer to be changed from below the ceiling. 5 Various embodiments of the invention can be arranged to offer some or all of the following features and/or advantages: 1. Fine ventilation apertures in the protector arrangement to prevent entry of insects or other contaminants. 10 2. A compact and stackable design for economical freighting, installation and carrying; 3. "Hole and plug" cable access options incorporated into the enclosures allows rapidity, smooth edged entry for fragile plastic leads a range of sizes to choose from and power tool not required for excess removal. 15 4. Multiple ventilation apertures for improved ventilation. 5. Inclusion of an intumescent coating around the insect proof ventilation perforations offers the best life for equipment and a safety feature against fires below ceiling spaces. This is because the intumescent coating swells up to cut off any air flow to the ceiling in case of fire. 20 6. Provides access to downlight and transformer from above ceilings and below. 7. Saves costly labour on 12 volt transformer lead extensions and avoids the long lead voltage drop syndrome. If leads are too short as supplied for new installation can be installed successfully by a retrofit method. 25 8. Standardises and simplifies safe down light assembly installation and service with an approved device. 9. Improves insulation coverage to the ceiling because the protector arrangements enable the installation to be safely installed closer to the down light than would previously be possible. 30 10.Folding or collapsing base option provides less assembly work, and handling/packing convenience and simple manufacturability. 11. They can be used for other appliances e.g. speakers etc.

WO 2004/018934 PCT/AU2003/001076 - 30 12.Various forms of the ceiling protectors protect the ceiling whilst not protruding below the ceiling thereby allowing flush mounting of down lights. 13. Saves electricians from needing to return after installation of insulation to 5 check safety aspect. 14. Allows cables to be suspended without leaving excess cable close to the high temperature down light globe at risk of rapid deterioration etc. 15.Cables do not need to run alongside transformers. 16. Base can be optionally fastened to the ceiling with metal or plastic C 10 shape clips. 17.Can save costs to the user as the protector arrangements prevent overheating and cut out of transformer etc. 18. Allows safe uncluttered ceiling joists (no transformers on them). 19. Transformers can be securely positioned. 15 20.They allow 3600 rotation of most spring clip down lights and won't damage the ceiling when a ceiling protector is used. The embodiments have been described by way of example only and modifications within the spirit and scope of the invention are envisaged. 20

Claims (20)

1. A protector arrangement for a down light including componentry, said protector arrangement including housing means arranged to protect and encapsulate the 5 componentry of the down light which extends beyond a surface of a wall or ceiling into a wall space or a ceiling space when the down light is mounted in said wall or ceiling, said housing means being arranged so that in use an isolating gap is maintained between the componentry and an inner surface of the housing means and wherein said housing means includes cable access means arranged so that the housing 10 means can be positioned about said componentry of said down light which was previously installed in said surface without need for disconnection of any electrical cable connected to said componentry, said cable access means being arranged so that the integrity of the encapsulation of the componentry is maintained during use of the protector arrangement. 15

2. A protector arrangement according to claim 1 wherein said housing means includes a part arranged in use to contact a portion of said componentry so as to thereby establish said isolating gap between the componentry and said inner surface of the housing means.

3. A protector arrangement according to claim 2 wherein the part arranged in use 20 to contact said portion of said componentry includes a lower edge portion of the housing means.

4. A protector arrangement according to claim 3 wherein the housing means includes a lower member and an upper member.

5. A protector arrangement according to claim 4 wherein the lower member rests 25 on a flange of the down light and is positioned between a pair of spring clips securing the down light to the surface.

6. A protector arrangement according to any one of claims 1 to 3 wherein said housing means is formed from at least two units which are arranged in use to surround the down light componentry. - 32

7. A protector arrangement according to claim 6 wherein the housing means is formed from two units, each unit including a base member and enclosure wall means, said base member being arranged in use to establish said isolating gap.

8. A protector arrangement according to claim 6 or claim 7 wherein the units are 5 connected together or arranged for connection together by means of complimentary male and female connectors, or by means of at least one connecting member.

9. A protector arrangement according to any one of claims 1 to 3 wherein said housing means is made from at least one piece of material joined and/or folded along respective join and/or fold lines so as to form said housing means and wherein at 10 least one of said join and/or fold lines acts as a hinge line so as to enable said housing means to be collapsed about said hinge line.

10. A protector arrangement according to claim 9 wherein the housing means is arranged so that it can be collapsed from a first configuration to a second configuration by applying pressure thereto so as to enable it to be passed through an 15 aperture in the surface and then to substantially return to its first configuration once the applied pressure is removed.

11. A protector arrangement according to any one of the preceding claims further including means for locating a transformer for the down light externally of the housing means and so that it is protected from direct contact with any material located on the 20 surface, said locating means locating the transformer substantially above the componentry of the down light or to one side thereof.

12. A protector arrangement according to claim 11 wherein the locating means includes a transformer platform or a transformer housing arranged to be mounted on or to the enclosure wall means. 25

13. A protector arrangement according to claim 12 wherein the transformer housing is arranged for connection to the enclosure wall means by threaded connectors or by complimentary male and female connectors or a snap type fit, or wherein the transformer housing is integrally formed with the enclosure wall means or is arranged for connection to the enclosure wall means by at least one connecting 30 member. -33

14. A protector arrangement according to claim 12 wherein the transformer platform includes a main body, a pair of side wings extending there from, means for pivotally engaging the transformer platform with an upper portion of the enclosure wall means, platform engaging means arranged to engage the transformer platform with 5 the enclosure wall means so that the transformer platform can be hung within the housing means and a handle for facilitating movement of the transformer platform when it is located on the housing means.

15. A protector arrangement according to any one of claims 12 to 14 wherein the transformer platform or transformer housing includes means for positioning a cable 10 extending from the transformer, said positioning means being arranged so that said cable can be positioned without need for disconnection from the transformer.

16. A protector arrangement according to any one claims 1 to 15 wherein the housing means includes at least one finger ledge formed on said inner space.

17. A protector arrangement according to any one of the preceding claims wherein 15 the housing means is made from a lightweight material, a fire retardant material, a non electrical conductive material, a plastics material, a clear material or an opaque material.

18. A down light assembly including a down light and a protector arrangement according to any one of the preceding claims. 20

19. A down light assembly according to claim 18 further including a transformer.

20. A protector arrangement substantially as hereinbefore described with reference to the accompanying drawings.