AU2013100156A4

AU2013100156A4 - Flexible light fitting

Info

Publication number: AU2013100156A4
Application number: AU2013100156A
Authority: AU
Inventors: Kenneth David Cleine
Original assignee: CLEINE KENNETH
Current assignee: CLEINE KENNETH
Priority date: 2013-02-15
Filing date: 2013-02-15
Publication date: 2013-04-04
Anticipated expiration: 2021-02-15
Also published as: AU2013100156B4

Abstract

A non-metallic light fitting manufactured from silicone rubber or similar flexible material capable of withstanding highly corrosive operational environments. The invention improves upon "down light fittings" of the known art by introducing full resistance to corrosion and greater sealing qualities. The preferred embodiment is an annular grommet moulded from a single homogenous piece of flexible, advanced material, capable of withstanding high operating temperatures, said grommet is electrically non-conductive, waterproof, weather and chemical resistant and is very economical to manufacture and purchase. Said fitting may be deformed by hand for the purpose of installation into the cut-out void of a ceiling or bulkhead panel (B) and will immediately reinstate to the original moulded shape thereby securing it to the mounting substrate (B). Using the same sequence of deformation a light bulb (G) is fitted and utilising the form, elasticity and memory of the material, said light bulb is housed securely by the flexible light fitting. Applicant and Inventor: Kenneth David Cleine ---------------------------------------------- Dated 15 th February 2013 DRAWINGS 1/2 SECTION "Z-Z" DIM "A" "c"l FIG 3.

Description

ORIGINAL COMPLETE SPECIFICATION INNOVATION PATENT Invention Title: "FLEXIBLE LIGHT FITTING" The following statement is a full description of this invention, Including the best method of performing it known to the Applicant. Applicant: Kenneth David Cleine Dated: 15 th February 2013 1. FLEXIBLE LIGHT FITTING TECHNICAL FIELD [0001] This invention relates to the electric lighting industry and can be suitably described as a "light fitting". In this industry, a "light fitting" is generally accepted as a fixture or assembly designed to house an electric light "globe" or "bulb" depending on one's choice of terminology. Such fittings usually offer a safe means of housing a light bulb as well as providing it with both a safe electrical connection and convenient access to change or replace the light bulb. Use of the word "bulb" is used throughout and means an electric light bulb or globe. [0002] This invention was developed originally to provide the market with a completely corrosion proof light fitting however, it will be appreciated that the invention may be used in numerous applications aside from where high resistance to corrosion is a key factor. The invention, by way of its innovation and novel design provides an economical alternative to the range of light fittings currently available and yet is in many ways a far superior product to some existing art.

2. BACKGROUND ART [0003] Manufactures associated with the lighting industry continually provide their retailers with an ever changing array of light fittings. Fashion and style determine a need for changing designs and it may be considered that a consumer demand for varying aesthetics plays a large role. Advancements in technology provide the industry with more compact and more efficient forms of light bulb and accordingly the humble light fitting is forever changing to accommodate. [0004] A specific lighting application may determine the need for a light fitting design that is specifically suited to that particular application such as a light fitting that will effectively operate within the harsh confines of a high-temperature, commercial oven or a light fitting that functions well while submerged below water in a pond or swimming pool. [0005] Among the specific environments requiring specially designed light fittings are the coastal, tropical regions of the world which provide some of the harshest conditions under which light fittings are expected to function. [0006] One common term for ceiling-mounted lights in a home is "down lights", as these lights generally illuminate in a downward direction in relation to the horizontal plane of the ceiling. Although the invention has been primarily developed as a "down light", it will be appreciated that it may be installed in any desirable orientation within ceilings, walls, bulkheads or panels situated in any plane. [0007] Low-voltage "tungsten halogen" light bulbs, as they are commonly known, have appeared over the past few decades as an alternative to the previously well known incandescent light globes that have been the standard lighting in homes for over a century.

3. [0008] More recently, "Light Emitting Diode" (L.E.D) light bulbs have been introduced in parallel with modern advances in technology. [0009] In much the same way as the first "low-energy" light bulbs were designed to fit into existing light fittings present in millions of homes around the world, the designers of LED light bulbs have made styles of LED bulb that will fit into light fittings and light bulb holders that were originally designed to accept tungsten halogen bulbs, thus negating the need to introduce a complete new range of light fittings and light bulb holders to accommodate the newer technology light bulbs. [0010] One known class of light bulb is an internationally popular shape and style of bulb known in the industry as the "MR1 6" lamp that features a standard, universal shape and size however, it is available in several technology types including both high and low-voltage tungsten halogen as well as LED. [0011] Due to the common occurrence and popularity of the MR16 style of light bulb, development work to date related to this invention has been carried out using this style of bulb however, it will be appreciated that a range of other styles of light bulb may be utilised with this invention or the invention utilised with other styles of light bulb. End of Section.

4. SUMMARY OF INVENTION Technical Problems Associated with Known Art. [0012] In conditions where an externally located light fitting is exposed to strong salt laden winds carrying moisture, high temperatures and humidity levels reaching 100% in combination with salt residues, many currently available light fittings sold as "outdoor light fittings" simply fail prematurely under such conditions. [0013] One class of known art is manufactured from steel which has been surface treated by way of commercial powder coating. This method of finish coating fails invariably under such extreme climatic conditions and rust, from the underlying corroding steel, appears rapidly after initial installation - quickly consuming the light fitting to a point where it becomes unsafe and unserviceable. [0014] Another known class of outdoor light fitting is manufactured from cast aluminium alloy and usually these fittings are also surface treated by painting or powder coating however the same inherent problems occur due to the inability of the surface treatment to withstand the harsh, extremely corrosive conditions over time. [0015] Corrosion problems caused by electrolytic action can occur with aluminium alloys and other metals being used as the body of the outdoor light fitting as high levels of moisture and salt, combined with dissimilar metals, can produce an electrolytic (electrochemical or voltaic) action. Differing metallic materials used to manufacture the light fitting, such as brass or stainless steel, or a mounting surface of galvanised iron or "zincalume TM", commonly used as building materials, can initialise and support a detrimental electrolytic action, as previously described, that will lead to corrosion of the light fitting, the metallic mounting surface, or both.

5. [0016] Another known class of outdoor light fitting is of a type manufactured from stainless steel. This class of fitting is often advertised and promoted as being suitable for outdoor use exposed to the elements in harsh coastal conditions where moisture and salt laden atmospheres prevail. It should be noted however that some variation in quality occurs within this class of fitting and unless regular maintenance is applied rust staining may still occur even in fittings manufactured from 316 grade stainless steel. Aside from this aesthetic problem the cost of purchasing such fittings is usually high. [0017] The less expensive stainless steel fittings often have non-stainless steel components in their assembly including the spring clips that retain the light fitting into the mounting surface and these non-stainless steel parts quickly corrode and fail in the harsh conditions rendering the entire light fitting unserviceable within a relatively short span of time. [0018] In conclusion it can be reasonably stated that very few of the currently available light fittings designed for outdoor installation in the harsh coastal conditions noted previously, will effectively endure such conditions over the long term - many not being able to maintain their operational integrity even within the short term. [0019] High levels of heat produced by the operation of some light bulbs can have a detrimental effect upon the useful life of the light fitting. In particular, the high temperatures produced when tungsten halogen bulbs are operating can cause premature deterioration of the light fitting and its surface coatings. [0020] Some known examples of light fitting comprise of complicated assemblies made up of many components and sub-assemblies making them over complex and often expensive due to elaborate manufacturing requirements. [0021] Some known examples of light fitting are more difficult to install than others and in most cases the method of mounting the light fitting to a surface or substrate requires using some form of fastener or spring clip and these items are often the weak component that fails under harsh conditions.

6. [0022] Some known examples of light fittings are manufactured from electrically conductive metal which may increase the level of risk associated with contacting electricity - particularly if poor earthing or a wet environment is present. [0023] Despite the fact that a specific range of light fittings have, according to their manufacturers, been specifically designed to withstand the harsh conditions of a tropical, coastal environment, only few of these in reality are in fact capable of providing a worthy, long term service of operation without failure or degradation. Solution to the Technical Problems Associated with Known Art [0024] "Corrosion" was the first problem to overcome and the prime reason for the development of this invention. The mandate was to provide a light fitting that would not corrode even under the harshest of climatic conditions and yet be capable of withstanding the high operating temperatures associated with some types of light bulb - particularly tungsten halogen bulbs which operate at extremely high temperatures. After conducting extensive research, and trials using various manufacturing materials, the solution finally came in the form of high-temperature resistant silicone rubber compounds. These advanced materials carry all of the properties necessary to overcome the problems. [0025] The particular heat resistant silicone rubber chosen for prototypes is one of many such advanced materials commercially and readily available. It can be easily moulded to practically any shape, is impervious to corrosion and will not suffer in any detrimental way from exposure to the weather and elements of the weather. It is relatively inexpensive, is not affected by elevated temperatures over long duration and has a range of very commendable mechanical properties. [0026] Of further benefit, this material is not electrically conductive and therefore, as a good insulator, risks associated with electricity are reduced. Being electrically inert also overcomes any problems associated with electrolysis.

7. [0027] The material requires no ongoing maintenance to ensure optimum performance and is aesthetically pleasing given that it can be prepared in a range of colours, surface finishes and hardness without the need for any surface coating or surface treatment. [0028] Utilisation of the said material in combination with prudent design practice has resulted in a simple, one-piece fitting that requires no other fixing components, fasteners or hardware to complete installation as a light fitting. [0029] The lack of complexity of design and use of the said material allows a very economical light fitting to be produced. Advantageous Effects of the Invention [0030] This invention serves to improve in many ways upon the designs of the vast range of proprietary light fittings currently available with the most notable attribute being its simplicity of design. [0031] This invention is a flexible light fitting manufactured from one homogenous piece of flexible material exhibiting no complexity. [0032] The invention is a light fitting capable of housing the industry standard "MR16" style of light bulb however it is not limited to this style or configuration of bulb. [0033] The invention is a light fitting capable of withstanding the harsh conditions of tropical, coastal regions however its usage is not limited to this particular application and it may be used in all climatic conditions harsh or otherwise. [0034] Unlike much of the known art, this invention will not rust, corrode or otherwise deteriorate prematurely because of exposure to a range of climatic and other elements including but not limited to water, sun, wind, ultraviolet light, salt laden atmosphere, heat, cold and humidity.

8. [0035] Similarly, it will not rust, corrode or otherwise deteriorate prematurely because of exposure to a range of chemicals or chemical rich atmospheres making it suitable for a range of commercial and industrial applications. [0036] The invention, in its preferred embodiment, has no surface coatings or treatments that may deteriorate over time. [0037] The invention is manufactured from material that is non-metallic and does not conduct electricity thereby negating any risk of deterioration due to electrolytic action. [0038] The invention requires no maintenance. [0039] The invention is a light fitting that requires no additional components, hardware or fasteners for the purpose of mounting it to a ceiling, bulkhead or otherwise a supporting substrate. [0040] The invention is a light fitting that is designed for an extended operating life in harsh conditions but will perform equally well when used under normal conditions. [0041] The invention is a light fitting that is designed to withstand the high operating temperatures associated with tungsten halogen bulbs over extended period of time without any detriment and will perform equally well will other types of bulb such as LED bulbs. [0042] The invention is a light fitting designed to be inexpensive because of its simplicity. The fitting is designed to be a high-performance, low-budget light fitting. [0043] The invention is a light fitting that is made from material that is not electrically conductive thereby enhancing the insulation properties of the fitting while reducing the risk of electric shock.

9. [0044] Being manufactured from a flexible material allows the light fitting to be temporarily deformed by hand for the purpose of installation in much the same way as a rubber bulkhead grommet is installed. Accordingly, the fitting is simple to install. [0045] By virtue of the innovative design, a water tight seal can be provided between the light bulb and the fitting as well as between the fitting and the bulkhead or panel into which it may be installed. This feature provides the light fitting with the ability to easily meet various standards that govern the ingress of moisture associated with electrical appliances such as an IP55 or an IP65 rating as examples of one type of said standard. Brief Description of Drawings. [0046] Referring to Drawing 1/2 , Figure 1. shows in one elevation that the invention is an annular shaped article being the light fitting. A cross section of the fitting is shown as SECTION "ZZ" at Figure 2. The moulded material allows for precise control over size and intricate shape and contouring to be included as the inside diameter of the fitting. This area is depicted as reference "P" on the drawing and the precise shaping of this area is important as the light bulb referenced as "G" in Figure 3. must locate precisely and accurately into the area to ensure that it is securely housed by the fitting. [0047] Referring further to Drawing 1/2, Figure 3. shows a dimension noted as "C" which is a diameter measurement that must correspond in a close ratio with the cut-out hole or void in the ceiling, bulkhead or panel that the light fitting is being mounted into. Similarly, the measurement noted as DIM "A" must correspond in close ratio with the material thickness of the ceiling, bulkhead or panel into which the fitting is mounted.

10. [0048] Referring to Drawing 2/2, this shows a cross sectional view of the light fitting housed within a ceiling, bulkhead or panel and housing a light bulb. The said ceiling, bulkhead or panel is detailed as "B" and the reference to DIM "B" relates to the thickness of the ceiling, bulkhead or panel into which the light fitting is mounted. Accordingly, DIM "B" must correspond in close ratio with the dimension shown as DIM "A" in Figure 3. on Drawing 1/2. [0049] The drawings depict the popular MR16 style of light bulb however it will be appreciated that the invention may accommodate other styles of light bulb. The drawings also depict an annular fitting however it will be appreciated that both the outer and inner shape of the fitting may be moulded in a range of shapes. Description of Embodiment and Best Mode of Carrying out invention [0050] The illustrated embodiment of the invention comprises an annular shaped grommet that serves as both the lamp holder and the light fitting however it will be appreciated that a range of different shapes could be easily adopted. [0051] Normal installation of a "down light", as these fittings are commonly known, involves first cutting or sawing a hole - usually a circular hole, in the ceiling, bulkhead or panel. Such hole will accommodate the light fitting and is normally made using a rotary "hole-saw" powered by a drilling machine. [0052] Some variation in thickness can be expected across the range of differing types of material that ceilings, bulkheads and wall panels are made from. Generally, such thickness may vary from 4mm to 6mm in the case of fibre reinforced cement sheets and up to 10mm to 12mm in the case of dry wall and plasterboards such as Gyprock T M . Such variation is easily accommodated both by varying DIM "A" of the invention and/or relying upon the flexibility of light fitting to accommodate a limited range of material thicknesses - DIM "B". It is anticipated that just two models of the fitting will accommodate all common ceiling thicknesses.

11. [0053] Preparation for installation of a down light fitting includes electrical pre wiring which must be carried out within the ceiling cavity allowing for expedient connection of the light fitting to the said pre-wiring and the installation of the light fitting within the hole that has been cut into the panel. [0054] There is no difference to the previously noted preparation process regardless of whether a down light fitting of known art or this invention is to be installed. Instead of the light fitting being retained into the panel by way of screws, spring clips or other types of fastener, as with the known art, this invention requires none of the said hardware to facilitate mounting of the light fitting. [0055] Furthermore, this invention may be effectively used as a retrofit or replacement of light fittings of the known art that may be inferior or have failed. [0056] The invention is manufactured from a flexible material which allows it to be temporarily deformed by hand for the purpose of installation in much the same way as a rubber bulkhead grommet is installed. The inherent memory of the material causes it to return instantly to its original moulded shape after being deformed by hand for the purpose of installation. In a similar way, the flexible fitting may be temporarily deformed to facilitate installation of the light bulb which it houses. Once installed, both the form of the moulded fitting and/or the elastic strength of the moulded fitting will retain the light bulb securely in place as well as anchoring the flexible fitting securely into the circular void provided within in the ceiling, bulkhead or mounting panel. [0057] In the preferred embodiment the invention is circular as is the ceiling cut-out however, it will be appreciated that a range of other different shapes could be easily adopted. End of Section.

Claims

12. CLAIMS 1. Non-metallic light fitting, able to securely house a light bulb in a ceiling, bulkhead or other panel, said fitting is manufactured from flexible material of rubber like consistency having the memory to retain its original shape if deformed and said fitting will not corrode when it is exposed to, installed and operated within harsh environments where corrosion may otherwise occur. 2. Non-metallic light fitting according to claim 1. wherein the said fitting is able to securely retain a light bulb in a captive position and simultaneously retain itself securely into a ceiling, bulkhead or panel by virtue of its own shape, form, elasticity and memory without the need to utilise any form of fastener, clip, spring or other form of ancillary hardware. 3. Non-metallic light fitting according to claim. or claim 2. wherein the manufacturing material used is a heat resistant silicone rubber and the said fitting is moulded as one homogenous piece. 4. Non-metallic light fitting according to either claim. or claim 2. wherein the design incorporates a heat shield as an integral part of the fitting. 5. Non-metallic light fitting according to either claim. or claim 2. wherein no part of the fitting is electrically conductive. 6. Non-metallic light fitting according to either claim 1. or claim 2. wherein a water tight seal is created between the said fitting and the said light bulb and/or the said fitting and the ceiling, bulkhead or panel into which the said fitting is mounted. 7. Non-metallic light fitting according to either claim 1. or claim 2. that may be used as a replacement or retrofit for existing art "down lights" that have failed or deteriorated in service. End of Section.