AU2018100492B4

AU2018100492B4 - A method for assembly and installation of continuous linear lighting

Info

Publication number: AU2018100492B4
Application number: AU2018100492A
Authority: AU
Inventors: Nathan Moffat; David O'driscoll
Original assignee: Brightgreen Pty Ltd
Current assignee: Brightgreen Pty Ltd
Priority date: 2018-04-16
Filing date: 2018-04-16
Publication date: 2018-12-13
Anticipated expiration: 2026-04-16
Also published as: AU2018100492A4

Abstract

A Method for Assembly and Installation of Continuous Linear Lighting [001] A method for on-site assembling and installation of continuous linear lighting is provided. The mounting system for linear lighting includes a continuous luminaire, i.e. at least two luminaire segments and at least one mounting bracket. The at least one mounting bracket includes a fixing surface and a resiliently flexible member. The method comprises the steps of identifying mounting points on the mounting surface, fastening the mounting brackets to the mounting surface, assembling the at least two segments at a suitable location by the installer via rail type engagement, engaging the mechanical fasteners between the segments, connecting the assembled luminaire to power sources and attaching the luminaire into the mounting brackets. The method of the present disclosure, as described in various embodiments, results in improved installation ergonomics and reduced installation time.

Description

A Method for Assembly and Installation of Continuous Linear

Lighting

FIELD OF TECHNOLOGY

[001] This disclosure relates generally to a mounting system for continuous linear lighting, and more particularly to a method for on-site assembling and installing continuous linear lighting.

BACKGROUND

[002] Typically, for the installation of a surface mounted linear lighting system, there is a need for a housing to be fixed to the mounting surface, luminaire segments to be joined and transformer wired prior to final assembly of the product. The installation methods of the existing linear lighting solutions involve a high proportion of the final product to be assembled on site since the final product needs to be disassembled for installation. |003] Further, the installation of existing linear lighting systems on different mounting surfaces requires varied installation techniques thereby increasing the complexity and duration of installation. For example a typical linear lighting system may consist of recessed, surface mounted and suspended luminaires within the same space and each mounting method requires a different installation technique. Thus, a homogenous linear lighting installation process across multiple mounting surfaces is not available.

[004] The existing solutions provides several alternatives to reduce the complexity of typical linear lighting installation. The existing installation methods offer detailed installation diagrams to the end user or provide qualified installers who know the system to remove the learning curve. As a result, on-site labour is required to install a linear lighting system. Further, the existing installation methods make use of electrical connectors on multiple pre-assembled sections, or make use of snap-fit light engines to speed up assembly into the luminaire housing. Moreover, an alternative of shipping longer sections is also considered to limit the amount of joints in the installation. |005] Furthermore, while installing a linear lighting traditional system, the installer may be on a ladder for majority of the installation working on segments of the luminaire which are directly above the installer. Working in this position limits access, increasing the duration of tasks and over a period of time, causing strain to the installer due to unfavorable body position. In addition, it is not easy for the installer to carry all the required tools or components while installing the linear lighting and therefore, the installer may need to do multiple trips up and down the ladder thereby increasing the installation time.

SUMMARY

[006] In order to solve at least some of the above mentioned problems, a method for quick assembly and installation of linear lighting is needed. A mounting system facilitating reduction in time, error and complexity for installation of linear lighting with the incorporation of a quick mounting system that removes the need to disassemble the final product for installation is needed. A system that reduces the complexity as the installation technique and avoids the installers multiple trips up and down the ladder is needed.

[007] Briefly, according to an exemplary embodiment, a method for on-site assembly of a continuous linear lighting system and installation within a space is disclosed. The method comprises the steps of identifying mounting points on the mounting surface; fastening the at least one mounting bracket to the mounting surface, i.e. the fixing surface; assembling the two or more luminaire segments via a rail-type engagement on-site at a suitable location; wiring the assembled luminaire segments to the available power source at the same location and attaching the assembled luminaire to the mounting bracket via a snap-fit engagement.

[008] The summary above is illustrative only and is not intended to be in any way limiting. Further aspects, exemplary embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE FIGURES |009] These and other features, aspects, and advantages of the exemplary embodiments can be better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: [0010] FIG. 1 illustrates an agile mounting system featuring its profile view prior to installation of the linear lighting, according to an embodiment of the present disclosure; 10011] FIG. 2 illustrates an isometric view and a profile view of an agile mounting system with assembled segment that is configured for installation of linear lighting, according to an embodiment of the present disclosure; |0012] FIG. 3A and FIG. 3B illustrates the step by step installation process of the agile mounting system, according to an embodiment of the present disclosure; |0013] FIG. 4 illustrates a perspective view of the sub-assembly of the agile mounting system, according to an embodiment of the present disclosure; and 10014] FIG. 5 illustrates various mounting bracket configurations for different mounting surfaces, according to an embodiment of the present disclosure. |0015] Further, skilled artisans will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the figures with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION

[0016] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the figures and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

[0017] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

[0018] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not comprise only those steps but may comprise other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by "comprises... a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components. Appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. |0019] At least one exemplary embodiment is generally directed towards a method for onsite assembling and installation of an agile mounting system for linear lighting. The agile mounting system for linear lighting includes a continuous luminaire and at least one mounting bracket. The continuous luminaire includes at least one segment of a light source housing and a light source. The at least one mounting bracket includes a fixing surface and a resiliently flexible member. The fixing surface is positioned adjacent to a mounting surface when installed and the resiliently flexible member is extending perpendicular to the fixing surface for receiving the continuous light source housing via a snap-fit engagement. |0020] The method as disclosed in the present disclosure reduces time and complexity of a linear lighting system installation. In one embodiment, the present disclosure discloses an agile or a quick mounting system that removes the need to disassemble the luminaire for installation. The secondary benefit of the method of the present disclosure is the consistency in the installation across multiple mounting surfaces, further reducing the time and complexity of a linear lighting system installation.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting. |0022] In addition to the illustrative aspects, exemplary embodiments, and features described above, further aspects, exemplary embodiments of the present disclosure will become apparent by reference to the drawings and the following detailed description.

[0023] FIG. 1 illustrates an agile mounting system 100 featuring its profile view with assembled segment that is configured for installation of linear lighting, according to an embodiment of the present disclosure. In particular, the profile view of the agile mounting system 100 illustrates a fixing surface 120, a mounting bracket 110, a resiliently flexible member 115, a luminaire 125, a light source housing 130, a light engine 135, and a light source 145. |0024] In one embodiment, the FIG. 1 illustrates the agile mounting system 100 configured for installation of linear lighting that removes the need to disassemble the luminaire (continuous luminaire 108) during the process of installation. |0025| Referring to FIG. 1, the agile mounting system 100 includes at least one mounting bracket 110 comprising the fixing surface 120 adjacent to the mounting surface when installed and the resiliently flexible member 115 extending generally perpendicular to the fixing surface 120 for receiving the continuous light source housing 130 via snap-fit engagement. |0026] The agile mounting system 100 further comprises the continuous luminaire 125. In one embodiment, the continuous luminaire 125 includes at least one segment of a light source housing 130 and light source 145. The continuous luminaire also includes a light engine thermally bonded to the light source housing and the light source. The resiliently flexible member 115 required for the snap fit engagement could be on the light source housing 130 instead of the mounting bracket 110.

[0027] In one example embodiment, during the process of installation the continuous luminaire 108 can be assembled and wired at the desired position of the installer prior fixing to the mounting surface via the at least one mounting bracket 110. In another embodiment, the at least one mounting bracket 110 can be modified for various mounting methods including recessed, surface mounted and suspended linear systems.

[0028] In one embodiment, the continuous luminaire 108 includes a light engine 135 which is thermally bonded to the light source 145 and light source housing 130. The light engine 135 is assembled with the light source housing 130 via a rail type engagement. When assembled (as shown by reference numeral 100-B), the length of the light engine 135 and light source housing 130 are offset such that the offset provides rigidity at the join of two segments, wherein the one segment includes the light source 145 and the light source housing 130 and the light engine 135 whilst also preventing light leaks. In the preferred embodiment the force required to disengage the light source housing 130 from the mounting bracket 110 is less than the force required to disengage the mounting bracket 110 from the mounting surface such that the mounting surface is not damaged when servicing the luminaire 125.

[0029] In one example embodiment, the continuous luminaire 108 could be fixed to the mounting bracket 110 via magnetic force instead of a snap fit. In another embodiment, the luminaire 125 could be fixed to the mounting bracket 110 via a push-to-close latch instead of a snap fit. In yet another embodiment, luminaire 125 could be fixed to the mounting bracket 110 via any combination of the above retention methods.

[0030] FIG. 2 illustrates an isometric view 200-A and a profile view 200-B of the agile mounting system 100 of FIG 1., with assembled segment that is configured for installation of linear lighting, according to an embodiment of the present disclosure. Referring to FIG. 2, the offset length 202 is used to provide rigidity between the segments, wherein the one segment includes the light source 114 and the light source housing 110 and the light engine 112 whilst also preventing light leaks. |0031] FIG. 3A and 3B illustrate a method for on-site assembly of a continuous linear lighting system and installation within a space, in accordance with embodiments of the present disclosure. The method initiates at step 302 with identification and marking of mounting points on the mounting surface by an installer. At step 304, the mounting brackets are fastened to the mounting surface by the installer using equipment known in the art. Further at step 306, the one or more luminaire segments are positioned as per the instructions.

[0032] At step 308, if the one or more luminaire segments as positioned can be lifted as a single piece, then the segments are first assembled using rail-type engagement (step 310). Next, at step 312, the mechanical fasteners are engaged between the at least two luminaire segments and the assembled luminaire is connected to the power source. At step 314, the assembled luminaire is then attached to the mounting brackets via the resiliently flexible member 115 in a snap-fit engagement. |0033] In an alternate embodiment, at step 308, if the one or more luminaire segments as positioned cannot be lifted as a single piece, then at step 322, one or more viable sub-assembly segments are identified by the installer. At step 324, each of the sub-segment is assembled via rail-type engagement, followed by engaging mechanical fasteners between the assembled segments at step 326. Further, at step 328, each of the assembled segment is connected to the available power source(s). In one embodiment, each of the assembled segment may be connected to one or more available power sources and after wiring an AC connector between the assembled segments, the assembled AC connector is attached to the mounting bracket(s). Further, at step 330, end caps are assembled on each of the segments and the assembled luminaire is attached into the corresponding mounting brackets.

[0034] As is evident from the foregoing disclosure of the method for on-site assembling and installation, the installation ergonomics and installation time are significantly improved when compared with prior art methods for installation of continuous linear systems.

[0035] Referring to FIG. 4, disassembled segments of a continuous luminaire are shown as shown by reference numeral 400-A. The continuous luminaire as shown by reference numeral 400-A are shipped to the installation site. The assembled segments of a continuous luminaire are shown by reference numeral 400-B. In one embodiment, the segments are joined on-site in the preferred location of installer. The joining of segments is easy task (plug and play) for the installer as described in the method of FIG.3. 10036] In a preferred embodiment of the present disclosure, the length of the light source housing (130) and the light engine offset (135) are assembled such that the assembling of two luminaire segments provides rigidity before a mechanical fastener is used to fix the parts. Each segment is assembled with an offset proportional to the corresponding segments either side of the luminaire segment.

[0037] Further, the method comprises fixing a secondary part to one luminaire segment which can then be used for the rail-type engagement instead of the offset as described earlier. The secondary part being a second luminaire segment, for example.

[0038] It is to be noted that fixing assembled luminaire segments together via a mechanical fastener provides a constant tension between each segment such that gaps are prevented at the joins when installed if a bending moment is applied. The mechanical fastener is recessed into a cavity on the top of the light source housing, this is the same cavity the mounting bracket attaches to. The mechanical fastener is, for example, a standard draw latch, cam-lock or a spring loaded clip. Constant tension between the two segments is maintained to ensure the join has no gaps and are held at the desired angle. The tension is provided with a spring loaded joining mechanism such as a pull latch or spring loaded lever (not shown). The spring loaded mechanism can be used with straight or angled segment joins depending on the requirement.

For angled joins additional brackets may be attached to the light engine to maintain rigidity at the joint. |0039] As is evident, actuation of the tensioned mechanical fastener is achieved without the use of a tool such that the complexity of the task and material requirements are reduced. Consequently, lower skilled labour could be used for a traditionally specialist task. |0040] Further, the method of the present disclosure comprises the steps of assembling a secondary film optic via snap-fit engagement between the light engine and the top surface of the primary lens optic. The film optic can be removed or replaced at any time after installation such that the beam characteristics of the luminaire can be change to meet new space requirements. 10041] As shown in Fig. 5, the at least one mounting bracket can be modified for various mounting methods including but not limited to surface mounted (502), recessed (504), suspended linear systems (506) and the like. In one embodiment, the method for installation of the suspended linear system (506) includes the steps of adjusting the cable height after the luminaire is assembled to the mounting bracket such that the position can be optimized to minimize glare.

[0042] As is evident from the foregoing disclosure, the force required to disengage the light source housing (130) from the mounting bracket (110) is less than the force required to disengage the mounting bracket (110) from the mounting surface (120) due to the snap-fit engagement at the resiliently flexible member (115). Thus ensuring that the mounting surface (120) is not damaged when servicing the luminaire.

[0043] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed.

Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. The scope of embodiments is at least as broad as given by the following claims.

Claims

Claims:

1. A method for on-site assembly of a continuous linear lighting system and installation within a space, the method comprising: fastening at least one mounting bracket to a fixing surface; assembling at least two luminaire segments via a rail-type engagement at a suitable location within the installation space, each luminaire segment comprising at least a light source housing and a light engine, such that the length of the light source housing and the light engine are offset to provide rigidity at the join of the two luminaire segments; wiring the at least one assembled luminaire, formed by assembling at least two luminaire segments, to mains power at the same suitable location; fixing the at least one assembled luminaire by a mechanical fastener for providing a constant tension between each luminaire segment such that gaps are prevented at the joins; attaching the at least one assembled luminaire to the mounting bracket via a snap-fit engagement.
2. The method as claimed in claim 1, wherein the mechanical fastener is configured for maintaining the luminaire segments at desired angles when a bending moment is applied.
3. The method as claimed in claim 2, wherein the mechanical fastener is recessed into a cavity where the mounting bracket is attached.
4. The method as claimed in claim 1, wherein the mechanical fastener is further comprising assembling a secondary optic film via a snap-fit engagement between the light engine and the top surface of a primary lens optic coupled to the light source.