AU2009202574A1 - Downlight Protector - Google Patents

Description

P/00/009 28/5/91 Regulation 3.2 ORIGINAL AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Invention title: "DOWNLIGHT PROTECTOR" Applicant: John Separovich and Rodney Trevor Powell Associated Provisional Application No.: 2008903253 The following statement is a full description of this invention, including the best method of performing it known to me: -2 "DOWNLIGHT PROTECTOR" Field of the Invention The present invention relates to a downlight protector for providing fire protection by preventing a downlight from becoming a potential fire hazard. 5 Background to the Invention Many contemporary commercial and residential buildings have downlights installed to provide improved lighting and aesthetic lighting effects within selected rooms. Most downlights typically operate on 12 volt with a power rating up to 50 watts. Each downlight is typically provided with its own 10 detached transformer to step down the 240 volt mains supply to 12 volt. The downlights are usually installed flush with the ceiling and protrude up into the roof space above the ceiling. The detached transformer is typically fixed to an adjacent ceiling rafter or joist, or simply left loose resting on the ceiling. When insulating material, such as insulation batts or bulk insulation, is installed in 15 the roof space, it normally rests on the ceiling and may overlay the downlight and/or transformer. There can be a substantial build-up of heat in connection with the downlight and/or transformer with temperatures sometimes reaching up to 2000 to 2500 C. Hence there is often a significant fire hazard associated with downlights, particularly if the downlight is located close to flammable 20 materials such as wooden ceiling joists. Prior art downlight covers exist to isolate the downlight from potentially flammable materials. However such downlight covers are typically made from moulded plastics materials and are bulky to package and transport. The present invention was developed with a view to providing an improved 25 downlight protector that can be packaged and transported in a collapsed condition and easily assembled prior to installation. References to prior art in this specification are provided for illustrative purposes only and are not to be taken as an admission that such prior art is part of the common general knowledge in Australia or elsewhere.

-3 Summary of the Invention According to one aspect of the present invention there is provided a downlight protector comprising: a rectangular elongate sheet of substantially inflammable material adapted to 5 be bent into the shape of a cylinder prior to installation; and, an attaching means for attaching the cylinder to a ceiling wherein, in use, when the downlight protector is installed in a ceiling surrounding a downlight it prevents the downlight from coming into contact with potentially flammable material. 10 Preferably the attaching means comprises a plurality of tabs provided at spaced intervals along a longitudinal edge of the rectangular sheet, each of the tabs being adapted to be bent at right angles to the plane of the sheet for fixing to the ceiling. Advantageously the downlight protector further comprises mounting means 15 for mounting a detached transformer on the cylinder when it is installed surrounding a downlight. Preferably the mounting means comprises at least one tab provided on the opposite longitudinal edge of the rectangular sheet, the at least one tab being adapted to be bent at right angles to the plane of the sheet for mounting a detached transformer thereon. 20 Typically fastening means are provided for securing the rectangular sheet in the shape of a cylinder after it is bent into shape prior to installation. Preferably the fastening means comprises at least one hook provided adjacent one end of the rectangular sheet, and at least one eye provided adjacent to the opposite end of the rectangular sheet, the at least one hook 25 being adapted to engage with the at least one eye and to be bent over so as to secure the rectangular sheet in the shape of a cylinder. Advantageously both the at least one hook and the at least one eye are cut out of the rectangular sheet of material itself. Throughout the specification, unless the context requires otherwise, the word 30 "comprise" or variations such as "comprises" or "comprising", will be -4 understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. Likewise the word "preferably" or variations such as "preferred", will be understood to imply that a stated integer or group of integers is desirable but not essential to the 5 working of the invention. Brief Description of the Drawings The nature of the invention will be better understood from the following detailed description of preferred embodiments of a downlight protector, given by way of example only, with reference to the accompanying drawings, in 10 which: Figure 1 shows a plan view of a first preferred embodiment of the downlight protector in its collapsed condition prior to installation; Figure 2 illustrates the downlight protector of Figure 1 in its assembled condition ready for installation; and, 15 Figure 3 illustrates the downlight protector of Figure 2 installed in a ceiling; and Figure 4 shows a plan view of a second preferred embodiment of the downlight protector in its collapsed condition prior to installation. 20 Detailed Description of Preferred Embodiments A preferred first embodiment of a downlight protector 10 in accordance with the invention, as illustrated in Figures 1 and 2, comprises a rectangular elongate sheet 12 of substantially inflammable material. In the illustrated embodiment the rectangular sheet is made from 0.5mm thick sheet of 25 aluminium. However it will be appreciated that any substantially inflammable material may be used, including a sheet of suitable plastics material. The rectangular sheet 12 should also preferably be adapted to be bent into the shape of a cylinder prior to installation. Depending on the material employed -5 the sheet 12 may retain its shape after bending or may require some means of securing it so that it retains its shape. In this embodiment the rectangular sheet 12 of aluminium is approximately 670mm in length and 200mm in height. When the sheet 12 is bent into the 5 shape of a cylinder it forms a cylinder approximately 200mm in diameter and 200mm in height as illustrated in Figure 2. Typically the sheet 12 is bent into the shape of a circular cylinder. However it may also be bent into other cylindrical shapes, including a cylinder with a rectangular cross-section, a cylinder with a semicircular cross-section or any other shape as required. The 10 important feature in each case is that, in use, when the cylinder is installed in a ceiling surrounding a downlight it prevents the downlight from coming into contact with potentially flammable materials. The downlight protector 10 further comprises an attaching means for attaching the cylinder to a ceiling. In this embodiment the attached means 15 comprises a plurality of tabs 14 provided at spaced intervals along a bottom longitudinal edge of the rectangular sheet, each of the tabs 14 being adapted to be bent at right angles to the plane of the sheet 12 for fixing to the ceiling. In this embodiment the tabs 14 are spaced at 25mm intervals and are each themselves about 25mm wide. Each tab 14 has a hole drilled through it to 20 permit easy fastening to the ceiling, for example, by staples and/or glue. Advantageously the downlight protector 10 further comprises mounting means for mounting a detached transformer on the cylinder when it is installed surrounding a downlight. In the illustrated embodiment the mounting means comprises at least one tab 16 provided on the opposite top 25 longitudinal edge of the rectangular sheet, the at least one tab being adapted to be bent at right angles to the plane of the sheet for mounting a detached transformer thereon. In this embodiment two tabs 16 are provided, spaced apart at a distance to permit a detached downlight transformer to be easily mounted thereon. Of course additional tabs or alternate mounting means may 30 be provided to suit other types of transformer as further described below. Typically fastening means are provided for securing the rectangular sheet 12 in the shape of a cylinder after it is bent into shape prior to installation. In this -6 embodiment the fastening means comprises two hooks 18 provided adjacent one end of the rectangular sheet 12, and two eyes 20 provided adjacent to the opposite end of the rectangular sheet 12. The two hooks 18 are adapted to engage with the two eyes 20 and to be bent over so as to secure the 5 rectangular sheet in the shape of a cylinder. Clearly other types of fastening means could be applied to secure the rectangular sheet 12 in the shape of a cylinder such as, for example, screws or some small bolts and nuts. However the advantage of the illustrated embodiment is that both the hooks 18 and the eye 20 are cut out of the rectangular sheet 12 itself, so that no additional 10 parts are required. Preferably a pair of cut-outs 22 are provided in the bottom longitudinal edge of the rectangular sheet 12 to permit electrical cable to enter or exit the hollow interior of the cylinder when it is mounted in a ceiling. Figure 2 illustrates the downlight protector 10 in its assembled condition. The 15 sheet 12 of aluminium is bent into the shape of a cylinder approximately 200mm in diameter. The hooks 18 are aligned with the eyes 20 and bent over so as to secure the sheet 12 in the shape of a cylinder. Each of the tabs 14 are bent outwards at right angles to the wall of the cylinder (the plane of the sheet 12), and the tabs 16 are bent inwards at right angles to the wall of the 20 cylinder. The downlight protector is now fully assembled and ready for installation. The whole assembly process takes less that a minute. Figure 3 illustrates the downlight protector 10 installed in a roof space surrounding a downlight 24 in a ceiling 26. The downlight protector 10 is attached to the ceiling by gluing the tabs 14 to the ceiling surface. A detached 25 transformer 28 for the downlight 24 is mounted on the tabs 16 (not visible) on the top edge of the cylinder, approximately 200mm above the surface of the ceiling. A 240 volt electrical power cable 30, for supplying power to the transformer 28, passes through the cut-out 22 up the inside of the cylinder. A layer of roof insulation 32 surrounds the downlight protector 10, and is kept 30 well away from the heat-producing electrical components by the wall of the cylinder. The open top of the downlight protector 10 ensures that the downlight 24 is kept well ventilated at all times to prevent the build-up of heat -7 during operation. If the downlight 24 with downlight protector 10 is installed prior to the insulation, the open top of the downlight protector 10 may be temporarily covered with a cap to prevent insulation material from entering the hollow interior of the cylinder. 5 Figure 4 shows a second preferred embodiment of the downlight which resembles the first embodiment in many ways and will not be described in detail again. Two sets of three tabs 16a, 16b, 16c are provided on a longitudinal edge of the rectangular sheet to permit a detached downlight transformer to be mounted thereon. The sets of tabs 16a, 16b and 16c allow 10 for the positioning of three varying sizes of transformers. Now that preferred embodiments of the downlight protector have been described in detail, it will be apparent that they provide a number of advantages over the prior art, including the following: (i) They ensure that the downlight is kept well away from potentially 15 flammable materials and therefore reduce the fire hazard. (ii) They are of simple construction and inexpensive materials. (iii) They are easily transported in bulk quantities in a collapsed (flat) condition. (iv) They can be quickly and easily assembled. 20 (v) There are no additional parts; they are fully self-contained. (vi) They can be readily modified to suit any downlight installation. It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing embodiments, 25 in addition to those already described, without departing from the basic inventive concepts of the present invention. For example, the attaching means and/or mounting means may comprise two of more brackets welded to the edge of the sheet of aluminium. However the advantage of the tabs is that they are formed from the same sheet of material. Therefore, it will be -8 appreciated that the scope of the invention is not limited to the specific embodiments described.

Claims (8)

1. A downright protector comprising: a rectangular elongate sheet of substantially inflammable material adapted to 5 be bent into the shape of a cylinder prior to installation; and, an attaching means for attaching the cylinder to a ceiling wherein, in use, when the downlight protector is installed in a ceiling surrounding a downlight it prevents the downlight from coming into contact with potentially flammable material. 10

2. A downlight protector as defined in claim 1, wherein the attaching means comprises a plurality of tabs provided at spaced intervals along a longitudinal edge of the rectangular sheet, each of the tabs being adapted to be bent at right angles to the plane of the sheet for fixing to the ceiling.

3. A downlight protector as defined in claim 1 or claim 2, wherein the 15 downlight protector further comprises mounting means for mounting a detached transformer on the cylinder when it is installed surrounding a downlight.

4. A downlight protector as defined in any one of the preceding claims, wherein the mounting means comprises at least one tab provided on the 20 opposite longitudinal edge of the rectangular sheet, the at least one tab being adapted to be bent at right angles to the plane of the sheet for mounting a detached transformer thereon.

5. A downlight protector as defined in any one of the preceding claims, wherein fastening means are provided for securing the rectangular sheet in 25 the shape of a cylinder after it is bent into shape prior to installation.

6. A downlight protector as defined in claim 5, wherein the fastening means comprises at least one hook provided adjacent one end of the rectangular sheet, and at least one eye provided adjacent to the opposite end of the rectangular sheet, the at least one hook being adapted to engage with the at 30 least one eye and to be bent over so as to secure the rectangular sheet in the shape of a cylinder. -10

7. A downright protector as defined in claim 6, wherein both the at least one hook and the at least one eye are cut out of the rectangular sheet of material itself.

8. A downlight protector substantially as herein described with reference to 5 and as illustrated in any one or more of the accompanying drawings. Dated this 26th day of June 2009 10 John Separovich and Rodney Trevor Powell By their Patent Attorneys 15 Janet Stead & Associates