AU2005100662B4 - Modular light assembly - Google Patents

Description

C051 1i MODULAR LIGHT ASSEMBLY Field of the invention [001] This invention relates to a lighting module, to a lighting system and to a method for installing lighting.

Background of the invention [002] A known method of installing lighting along road or train tunnels or the like, involves installing individual light assemblies or luminaires, one at a time. The process of doing so usually involves preparing the wiring, and connecting it to each respective luminaire in turn.

This work is highly repetitive and time consuming. Furthermore, such lighting is usually installed just under the ceiling of the tunnel in question, and this requires the installer to stand on a hoist a number of metres above the ground, and to install the lighting above the installer's head. Accordingly, the work is also awkward and potentially dangerous. As a result of these conditions, the work involved in installing such lighting can be costly.

[003] It is an object of the invention to overcome or substantially ameliorate one or more of the disadvantages of the prior art, or to provide an alternative to known lighting and methods of installing known lighting.

[004] In this specification, the term "cable ladder" means a structure of a ladder-like configuration, for supporting cables.

[005] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

C05111i 2 Summary of the invention [006] Insert Paragraphs According to a first aspect of the invention there is provided a lighting module for mounting on at least one lighting support surface, the module including: a support structure; attachment means configured for attaching the support structure to the at least one lighting support surface; a light assembly mounted on said support structure; and an electrical junction means supported by the support structure, wherein the light assembly is electrically connected to the junction means and wherein the junction means is adapted to enable electrical connection to the junction means of another, successive said module.

[007] In a preferred embodiment, the support structure is an elongate cable ladder.

[008] In a preferred embodiment, the module includes a plurality of said light assemblies mounted on said support structure.

[009] The light assemblies are preferably mounted on the support structure so as to be positioned along the length of the support structure.

[010] In a preferred embodiment, the attachment means includes a plurality of preferably elongate module supports for connection to the at least one support surface and configured for supporting the support structure thereon. Preferably, each module support extends substantially transversely relative to the support structure. Preferably, each module support is configured for attachment to a respective support element which descends from said at least one support surface.

CO5111i 3 [011] In a preferred embodiment, each light assembly includes at least one light source and a back reflector. Preferably, each light assembly includes at least one light source in the form of a fluorescent tube. Each light assembly preferably includes a protective cover, which is preferably movable between a closed position in which the cover extends across the at least one light source of the respective assembly and an opened position suitable for providing access to the at least one light source.

[012] In a preferred embodiment, the module includes a plurality of mounting brackets, with each light assembly being mounted on the support structure by at least a respective one of said mounting brackets.

[013] In a preferred embodiment, at least one light assembly of the module is electrically connected to the junction means by at least one electric cable extending from that light assembly to the junction means.

[014] In a preferred embodiment, the electrical junction means includes a junction box.

Then, preferably, the junction means includes electrical connectors in the junction box, for securing ends of electric cables extending from at least one of the light assemblies. In a preferred embodiment, the junction means includes at least one module-interconnection electric cable for extending from the junction box to the junction box of another said module.

[015] In one preferred embodiment, the junction means is adapted for electrical connection to a cable extending from a light assembly of another said module.

[016] According to a second aspect of the invention there is provided a lighting system including a plurality of lighting modules according to the first aspect of the invention or preferred embodiments thereof, wherein the junction means of at least one of said modules is electrically connected to the junction means of another of said modules.

C0511 ii 4 [017] In a preferred embodiment, said modules are arranged in a series configuration and said other module is a next successive module in said series. Preferably, the electrical connection of the junction means of the at least one module to the junction means of the other module is by electrical cable. In a preferred embodiment, the electrical connection of the junction means of the at least one module to the junction means of the other module is for supplying at least electrical power to that other module.

[018] In a preferred embodiment, the junction means of a plurality of said lighting modules are electrically connected to one another.

[019] In one preferred embodiment, a light assembly of at least one of said modules is electrically connected to the junction means of another of said modules which is preferably a next successive module.

[020] According to a third aspect of the invention there is provided a method of installing lighting on at least one lighting support surface, the method including the steps of: providing a lighting module including: a support structure; attachment means configured for attaching the support structure to the at least one lighting support surface; a light assembly mounted on said support structure; and an electrical junction means supported by the support structure, wherein the light assembly is electrically connected to the junction means and wherein the junction means is adapted to enable electrical connection to the junction means of another, successive said module; and securing the lighting module to the at least one lighting support surface.

C05111i [021] In a preferred embodiment, the step of securing the lighting module includes the step of attaching the module to at least one support element suspended from the at least one lighting support surface.

[022] In a preferred embodiment, the attachment means includes a plurality of preferably elongate module supports for connection to the at least one support surface and configured for supporting the support structure thereon, and the step of attaching the module to at least one support element includes the step of attaching each module support to at least one support element.

[023] In a preferred embodiment, the steps of providing a lighting module and securing the lighting module are carried out in respect of a plurality of lighting modules, the method including the further step of effecting electrical connection between the modules of said plurality by electrically connecting the respective junction means to one another.

[024] In a preferred embodiment, the electrical junction means includes a junction box and at least one module-interconnection electric cable: wherein the step of effecting electrical connection between the modules, for each two modules which are so connected to each other, includes the step of electrically connecting the junction means of the two modules to each other using the at least one module-interconnection cable of one of the two modules.

[025] Preferably, then, the step of providing a lighting module includes the step of disposing part of the module-interconnection electric cable adjacent the junction box.

Brief description of the drawings [026] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: C05111i 6 [027] Figure 1 is a schematic plan view of a lighting module according to an embodiment of the invention; [028] Figure 2 is a schematic side elevation of the lighting module of Figure 1; [029] Figure 3 is a schematic partly cut-away end elevation of the lighting module of Figure 1; and [030] Figure 4 is a schematic elevation of a junction box of the module of Figure 1.

Detailed description of the embodiment or embodiments [031] Referring to the drawings, the lighting module 6 includes a cable ladder 8 which extends the length of the module. The cable ladder 8 has elongate side members 10, each having an upper outwardly extending flange 12, and a lower outwardly extending flange 14. The cable ladder 8 further includes cross members 16 which interconnect the side members 10 at spaced positions along the length of the ladder.

[032] The module 6 includes attachment means in the form of a pair of elongate supports 18 which extend transversely relative to the ladder 8. Each support 18 has a pair of connection holes [033] The module 6 also includes three light assemblies in the form of luminaires 22.1, 22.2 and 22.3. Each luminaire 22.1, 22.2 and 22.3 includes a housing 24 of which an inner face 26 is reflective. The luminaires 22.1, 22.2 and 22.3 also include end walls 28 on which are mounted connectors 30 for receiving electrical connections of light sources in the form of fluorescent tubes 32.

[034] Each luminaire 22.1, 22.2 and 22.3 is mounted on the cable ladder 8 by means of a pair of mounting brackets 34. Each mounting bracket 34 has a pair of end portions 36 and a central portion 38 positioned lower than the end portions.. The luminaires 22.1, 22.2 and 22.3 are attached to their respective pairs of mounting brackets 34 by means of the respective housing 24 C05111i 7 being bolted, or joined in any other suitable way, tothe central portions 38. The brackets 34, in turn, are mounted on the cable ladder 8 by means of the end portions 36 being secured by bolts to the lower flanges 14 of the cable ladder.

[035] The luminaires 22.1, 22.2 and 22.3 also have covers 42. As shown in Figure 3, each cover 42 includes a frame 42.1 which is connected to the respective housing 24 by a hinge (not shown) at an edge 44 of the housing 24, and a transparent screen 42.2 of glass or other suitable material mounted on the frame for allowing the transmission of light therethrough.

[036] Each cover 42 can be moved from the closed position shown in Figure 3, in which it extends below the fluorescent tube 32 of the respective luminaire 22.1, 22.2 or 22.3, so as to substantially close off the respective housing 24, and an opened position as shown in broken lines in Figure 3 which provides access to the fluorescent tube.

[037] Mounted on the side of the cable ladder 8 is a junction box 46 which is shown in detail in Figure 4. The junction box 46 has a box housing 48 which includes side walls 50 and 52, upper and lower walls 54 and a back wall 56. The back wall 56 has bolt apertures 58 at each of its four corners for mounting the junction box 46 on a mounting plate 60. The mounting plate in turn, is mounted on the upper flange 12 and lower flange 14 of the cable ladder 8 as shown in Figure 3.

[038] Mounted on the back wall 56 of each junction box 46 is a bank of electrical connectors including "active" supply connectors 68 and 68.1, "neutral" supply connectors 70 and 70.1, and an "earth" supply connector 72. In addition, end plates 62, 64 and 66 are used to firmly locate the terminals 68, 68.1, 70, 70.1 and 72. The end plate 64 electrically isolates the "active" supply connectors 68 and 68.1 from the "neutral" supply connectors 70 and 70.1.

[039] Joined to the side wall 50 is a supply-in gland 74 and a first light assembly gland 76, each of these glands opening through apertures (not shown) in the relevant side wall into the junction box 46. Similarly, on the other side wall 52, there are mounted two further light C05111i 8 assembly glands 78 and 80 and a supply-out gland 82, each of these glands also opening through apertures (not shown) in the relevant side wall into the junction box 46.

[040] The lighting module 6 is designed to be assembled at a location other than the location at which it is to be installed for use. The assembly involves securing the luminaires 22.1, 22.2 and 22.3 to the cable ladder 8 as described above, and then connecting electric cables 84 and 86 between the luminaires 22.1 and 22.3, respectively, and the junction box 46. It will be appreciated that each of these cables 84 and 86 has separate electrical wiring for "active", "neutral" and "earth" connections, which are electrically connected to the connectors 30 which hold the fluorescent tubes 32 of the respective lighting assemblies 22.1 and 22.3. Thus, these cables 84 and 86 are in electrical connection with the fluorescent tubes 32.

[041] Accordingly, the cable 84 connected to the luminaire 22.1 is fed through the light assembly gland 76, and the respective "active", "neutral", and "earth" wires forming part of that cable are connected to suitable light assembly connectors 68, 70 and 72 respectively, at appropriate positions as indicated in broken lines in Figure 4. Similarly, the cable 86, which is in electrical connection with the luminaire 22.3, is fed through the gland 78, and its "active", '"neutral", and "earth" wires connected to suitable light assembly connectors 68, 70 and 72 respectively, also as shown in broken lines in Figure 4.

[042] A corresponding cable 88 is electrically connected to the fluorescent tube 32 of the middle luminaire 22.2 but, in this embodiment, is not connected to the junction box 46.

Rather, it is connected to the corresponding junction box of an adjacent lighting module, as described in more detail below.

[043] Once the lighting module 6 is assembled as described above, it can be brought to the site where it is to be installed for use. In the embodiment described, this site is a tunnel such as a road or railway tuhnel.

C051 1i 9 [044] The installation involves attaching the supports 18, which support the cable ladder 8, to support elements in the form of droppers 90 which are attached to, and suspended from, the ceiling 91 of the tunnel. Each dropper 90 may be in the form of a chain or rod, and its nature and manner of attachment to the ceiling 91 in question will be as understood by those skilled in the art.

[045] The droppers 90 are attached to the supports 18 by passing threaded lower ends of the droppers through the connection holes 20 of the supports, and then securing them in place by applying nuts 92 to those lower ends. Accordingly, once the supports 18 are secured in this manner, the lighting module 6 is effectively suspended from the ceiling 91 of the tunnel.

[046] The same process is repeated for further similar lighting modules along the length of the tunnel, so that the lighting modules are disposed in a series configuration relative to one another.

[047] Once the other lighting modules are installed, the lighting module 6 can be placed in electrical connection with the next successive lighting module, and this can then be repeated for the successive modules. The lighting module 6, assuming that it is the first module in the series of modules, can then be electrically powered. This involves extending a power supply cable 94 through the power-in gland 74, and connecting the "active", "neutral", and "earth" wires of the power supply cable to the supply connectors 68, 70 and 72. A power transmission cable 96 also has its "active", "neutral", and "earth" wires connected to the supply connectors 68, 70 and 72, and extends out of the junction box 46 via the supply-out gland 82. This cable 96 then extends through the supply-in gland of the junction box of the next successive lighting module, that is, the gland corresponding to the supply gland 74. The "active", "neutral", and "earth" wires of the other end of the cable 96 are then connected to the relevant connectors of that successive junction box, that is, the connectors corresponding to the connector 68, 70 and 72, so as to provide electrical power to that next module.

[048] As mentioned above, the cable 88 connected to the luminaire 22.2 is not connected to the junction box 46 of the lighting module 6, but rather, is connected to the junction C05111i box of the immediately succeeding module in the series of lighting modules. Accordingly, the cable 88 extends through the light assembly gland of the junction box of the next module (that is, the gland corresponding to the gland 80 of the module 6 illustrated) with its "active", "neutral", and "earth" wires connected to the relevant light assembly connectors corresponding to the connectors 68, 70 and 72.

[049] The connection of the middle luminaires of each module to the junction box of the next successive module, as described above, is a safety feature. Thus, if the junction box (corresponding to the junction box 46) of a particular module becomes dysfunctional for any reason such as fire, then although this may result in the two outer luminaires of that module (corresponding to the luminaires 22.1 and 22.3) being deactivated, the middle luminaire of that module (corresponding to the luminaire 22.2) which is not connected to that junction box, may remain active and hence illuminated.

[050] It will be appreciated that the lighting module 6, when initially assembled, may be provided with its power transmission cable 96 already connected to the relevant connectors 68, and 72, with this cable being coiled outside the junction box 46 after having already been fed through the supply-out gland 82 for connection to the junction box of the next successive lighting module, during installation, dependent on circuit configuration requirements. Indeed, for the purpose of facilitating the interconnection of the various modules, apart from coiling the cable 96 outside the junction box 46 as described above, the cable itself can be pre-prepared by removing the insulation from its wires at its free end so as to expose the wiring, so that the cable is ready to be simply connected to the relevant connectors of the junction box of the next successive lighting module.

[051] Similarly, the cable which is to extend from the junction box of each module to the central luminaire of the preceding lighting module (that is the luminaire corresponding with the luminaire 22.2) can also be provided pre-prepared and coiled outside the relevant junction box to facilitate connection to the preceding lighting module.

C05111i 11 S [052] In a configuration in which the module 6 is the first module in the series of modules, it will be appreciated that the power supply cable 94 is for providing power to the lighting module 6, with power to the series of successive modules being provided by the power transmission cable 96, and the successive power transmission cables corresponding to the cable 96. It will thus be appreciated that the electrical connection to the luminaires of the lighting S module 6 and those of the successive lighting modules are parallel connections.

INO

S [053] In another embodiment, instead of having, as described above, only one power supply cable 94 into the junction box 46 and one power transmission cable 96 extending to the next successive lighting module, there may be an additional power supply cable (not shown) from an uninterruptible power supply (UPS) (not shown), and a corresponding UPS power transmission cable (not shown) extending from the junction box to the junction box of the next successive lighting module. In this case the UPS power supply cable may extend through a UPS supply-in gland 102 mounted on the side wall 50 and which opens through an'aperture (not, shown) into the junction box 46. Similarly, the UPS power transmission cable can extend through a UPS supply-out gland 104 mounted on the side wall 52 and which opens through an aperture (not shown) into the junction box 46. In this embodiment the "active", "neutral" and "earth" wires of the UPS power supply and transmission cables are connected to suitable ones of the light assembly connectors 68.1, 70.1 and 72. Furthermore in this embodiment, the luminaire 22.1 is for UPS purposes. To this end, the "active", "neutral" and "earth" wires of the cable 84 are connected to particular ones of the light assembly connectors 68.1, 70.1 and 72 which are electrically connected to the respective light assembly connectors to which the wires of the UPS power supply and transmission cables are connected, but electrically isolated from the other light assembly connectors.

[054] Thus, in the event of a power failure where the power supplied via the power supply cable 94 is terminated, a suitable UPS power supply can provide power to the junction box 46 and to the junction boxes of the remaining modules via the UPS power transmission cables so as to illuminate only the luminaire 22.1 and corresponding luminaires of the other modules, but not any of the other luminaires.

C05111i 12 [055] As in the case of the other cables described above, the UPS power transmission cable may be provided coiled outside the junction box 46 and pre-prepared, when the lighting module 6 is initially assembled.

[056] The construction of the lighting module 6 thus facilitates installation of lighting, generally, at the installation site. This is because the lighting module 6 and each similar module are pre-assembled at a first location and transported as modular units to the installation site where they are attached to the droppers 90 as described above.

[057] With power supplied by the power supply cable to the first lighting module in the series, such as the module 6, then in order to electrically connect the successive modules to allow for the supply of electrical power to each one, in one embodiment, all that is required is to interconnect the modules using the power transmission cable 96 and corresponding cables of the other modules, which extend from each junction box to the next. Where appropriate, the interconnection may also involve connection of the relevant cable (corresponding to the cable 88) from the central luminaire of each module (corresponding to the luminaire 22.2) to the junction box of the succeeding module as described above. Furthermore, where appropriate, the interconnection may involve the connection of the UPS cables as described above. This avoids having to install each luminaire separately, and the associated steps of preparing, manipulating, and connecting the relevant cables and wires to each such luminaire.

[058] In the above description, where reference is made to the module 6, then unless the context provides otherwise, similar description applies to other modules which are to be connected in the series configuration of lighting modules as referred to above.

[059] Although the invention has been described in relation to specific embodiments above, it will be appreciated by those skilled in the art that it is not limited to those embodiments, but may embodied in many other forms. For example, the configuration of the lighting module might not be exactly as shown in respect of the lighting module 6. In particular, there may be different numbers and configurations of luminaires on each module, different numbers and configurations of the supports corresponding to the supports 18, different C05111i 13 configurations of the connectors 62, 64, 66, 68, 68.1, 70, 70.1 and 72, and different locations for the mounting of the junction box. In addition, while some embodiments may include provision for UPS supply and transmission, other embodiments might not. Furthermore, while in some embodiments as described above, one or more of the luminaires of a particular module may, instead of being connected to the junction box of that module, be connected to the junction box of a preceding or succeeding module, in other embodiments each of the luminaires of a particular module may be connected to the junction box of that module itself.

[060] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of'. A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

[061] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[062] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims (4)

1. A light module including: a support structure adapted to support one or more light units and to be attached to a support surface; one or more a light units attached to the support structure by attachment means; and a first electrical junction box to which an electrical supply line can be connected; wherein at least a first light unit is connected to the first junction box to receive electrical power to energize the light unit; the first junction box being adapted for electrical connection with one or more adjacent or alternate light modules.

2. A light module as claimed in claim 1, wherein the first junction box is adapted to enable electrical connection to a second light unit of a second light module on a second support frame; whereby at least one light unit of each light module can be powered from the junction box of another light module.

3. A series of light modules as claimed in claim 1 or claim 2, wherein alternate light modules are connected to separate power sources.

4. A method of installing lighting on at least one lighting support surface, the method including the steps of pre-assembling a plurality of light modules as claimed in claim 2 or claim 3: securing the lighting modules to the lighting support surface; electrically connecting the electrical junction boxes of adjacent or alternate lighting modules. A method of installing lighting on at least one lighting support surface as claimed in claim 4 wherein, for each two light modules to be interconnected, there is at least one module-interconnection electric cable, and wherein the step of effecting electrical connection between the modules, for each two modules which are to be connected to each other, includes the step of electrically connecting the junction boxes of the two modules to each other using the at least one module-interconnection cable. Dated this 2 7 th day of March 2006 Downer Engineering Power Pty Limited Attorney for the applicant Halford Co.