WO2000031466A1

WO2000031466A1 - Universal built-in spotlight support box and relative fitting tool

Info

Publication number: WO2000031466A1
Application number: PCT/IT1999/000370
Authority: WO
Inventors: Celestino Costa
Original assignee: Celestino Costa
Priority date: 1998-11-25
Filing date: 1999-11-16
Publication date: 2000-06-02
Also published as: ATE343092T1; EP1147339A1; PT1147339E; AU1295800A; DE69933701D1; EP1147339B1; ITFO980031A1; IT1306388B1

Abstract

This special box is a kind of universal built-in box made up of a main body (C) and a cap which is intended for housing spotlights supported by spring-arms (S). The main body contains an inner series of step circles (A) which form a winding spiral according to the shape of the box. Such rings correspond to as many outer indents to be chosen in accordance with the type of spotlight to install. The cap can be exactly coupled with the main body and further reduced in its upper part as well. This way, three different box volumes can be obtained and used accordingly on the basis of the length of the spotlight to be installed. A specific tool for installation allows a quick and exact positioning of the box prior to any fixing procedure.

Description

DESCRIPTION UNIVERSAL BUILT-IN SPOTLIGHT SUPPORT BOX AND RELATIVE FITTING

TOOL

Spotlights are usually embedded directly into false ceilings or walls made of plaster-paper which can easily be drilled according to the diameter required to accomplish a proper installation.

Thus each lights set is fixed by joining the plaster-paper slab between the spotlight outer frame and the two spring-arms stretching and opening out on the back.

So, even if this way of lighting has been very much used lately and more and more fitters as well as customers have started appreciating it, they can still dispose of no suitable means when spotlights are to be embedded into brick and cement walls or ceilings and not into plaster-paper slabs. Thus, on such occasions, you need makeshift remedies which, at best, consist in making a sort of built-in box out of reduction sleeves for fluid discharge pipes when the overall dimensions of the spotlight allow you to.

Being such sleeves composed of two parts with different diameters, the fitting in of the spotlight into the smaller section allows the opening out of the spring-arms which hold up the spotlight inside the larger section.

In case you can find reduction sleeves with a smaller diameter compatible with the one of the spotlight, they can be cut along the length required to install them, even if by means of some makeshift, into a gap inside the wall where they are fixed with cement mortar.

In some cases you also need to adjust the diameters of such sleeves by inserting a reduction ring made of metal or plastic.

Clearly such a procedure prevents the work from being utterly satisfactory and weighs heavily on the spotlight installation costs. Moreover, such costs cannot even be estimated since they very much depend on the availability of reduction sleeves which can be compatible with the spotlight dimensions.

You should also take into account the fact that the range of spotlights currently on the market is quite wide and varied as far as overall dimensions, design and employed materials are concerned. Therefore you can also find spotlights made of glass or baked clay which, besides being much heavier than the ones made of metal, are also unsuitable for such reduction sleeves. In fact they have no hold whatever and the limited opening out of the spring-arms allows no proper grip.

The purpose of this idea is to overcome all the above-mentioned troubles and offer the spotlights installer a built-in box which is universal, since it can be easily adjusted to the overall dimensions of each spotlight, and suitable also for temporary installation during the fixing with expanded polyurethane or cement mortar by means of a specific tool described and included in this industrial patent.

You should also keep in mind that the new universal built-in box is designed to allow a proper loss of heat. Moreover, even if it is intended mainly for solving any kind of practical problem concerning the spotlight installation into brick or cement walls/ceilings, this special box is can also be employed as a safe and insulated housing for the spotlight, the transformer and respective electrical connections.

Further qualities and features will be described by help of 16 drawings to be regarded purely as an indication.

- Fig. 1 - 2 - 3 show the side views of the box main body;

- Fig. 4 shows the box main body from above;

- Fig. 5 - 6 show the box cap from above and from below respectively;

- Fig. 7 - 8 show the side views of the box cap;

- Fig. 9 - 10 show the possible variations in the box volume according to cap positioning or reduction through cutting;

- Fig. 11 - 12 show a section of the 3 -arm device of the special tool for the built-in box installation and the device as seen from above;

- Fig. 13 shows a section of the rod that slides inside the 3 -arm device;

- Fig. 14 shows both the rod and the 3-arm device as a whole, thus forming the special tool for the built-in box installation;

- Fig. 15 shows a vertical section of a built-in box installation through the special support;

- Fig. 16 shows a vertical section of a spotlight installation once finished.

From these pictures you can see, first of all, how this new built-in box is composed of a main body and a cap with different position slots. Every part is obtained through moulding and is made of plastic material (possibly in light colours) in order to obtain better light reflection and less heat absorption. The main body and/or the cap of this built-in box have some pre-cut parts ready to be detached in case of need to let electric wire sheaths pass by and loss of heat take place by using more sheaths or pipes which go through the box fixing material and reach the brick hollows. If necessary, they can also reach outside the wall.

The main body, which is cone-shaped, is larger at the top, so that it can be stacked up during stockpiling and transport, and smaller at the bottom. Both ends are open. The upper end, which is larger in diameter and reaches the inner part of the wall, has to be capped whereas the bottom end, which is used for the spotlight installation, sticks out as a reference point for plaster finishing. For that purpose a special device has been designed (see Fig. 11 - 12 - 13 and 14) which allows perfect positioning and sticking out of the box as well as its proper fitting during the fixing procedures (be it with cement mortar, expanded resins, etc.). The main body contains an inner series of step circles which form a winding spiral according to the shape of the box. Such rings correspond to as many outer indents to be chosen in accordance with the type of spotlight and, at the same time, allow a better hold of the inner spring-arms directly onto the ring levels.

Having a closer look at the built-in box as a whole (see Fig. 1 - 2 - 3 and 4) one can see that the main body is nearly cone-shaped at the bottom and consists of a series of rings with increasing diameters which fit to any type of spotlight. The upper part has a similar shape with two side "P" sections which, facing the opposite direction, permit the spotlight spring-arms to open wide properly.

In order to make the removal of the part under the ring chosen for the fitting up of the spotlight easier, the "A" ring connection is pre-cut since it is limited to short thickening sections. Moreover the cutting procedures can be easily carried out by means of a jigsaw and are made even easier because of the slots placed on the bottom part of the "A" section. Near the upper edge of the main body there are some pre-cut "B" sections which allow - if necessary - a proper opening to let electric wires pass by. Since the height of the box can be considerably changed by its cutting - to be carried out according to the diameter of the spotlight to install as well as its overall dimensions - the cap has been given two different positions ("Q" and "R") where it can be coupled with the box. The box itself can also be reduced if cut along the pre-cut

"C" line. This way, three different volumes are available and can be used accordingly (Fig. 9 -

10).

The cap (Fig. 5 - 6 - 7 - 8) is adapted to and shaped according to the upper edge of the box main body. Its central stick "F" helps the setting of a possible connection. A sealing system "E" surrounds it and is exactly coupled with the application tool (on the "M" area) designed for the fixing procedures. Two plastic tangs define the coupling set-up of the "M" device which can thus be removed, once the box has been fixed into the wall, by simply rotating it in the opposite direction as the one used for coupling.

The tool for installation (see Fig. 11 - 12 - 13 - 14) is composed of a 3-arm radial device (Fig.

11 - 12) and a "L" flat section against which the bottom edge of the built-in box is to be eventually located. This section is lower than the three "I" arms stretching towards the wall and above the hole intended for the box housing and the fixing material (cement mortar, expanded resins, etc).

The difference in height between the "L" section and the "F arms allows a proper installation

(protruding) of the box and enough plaster for the positioning of the spotlight frame which is kept in place by the spring-arms typical of any built-in spotlight.

The radial device is also made up of a cylindrical section, jutting out on the lower side, which is centred and perpendicular to the "L" flat section. There is a "U" locking slot through which the stick shown in Fig. 13 can be easily locked. The upper part of the stick is equipped with an "M" device which locks the box against the "L" flat section.

The above mentioned two vertical tangs, stretching (opposite to each other) from the device shown in Fig. 13, help to keep the box cap properly hooked.

Whenever the box has to be embedded into a ceiling, the stick placed at the bottom of the box will be applied to an extensible pole so as to create a framework to put in tension between the floor and the ceiling. This way, the installation tool will be supported by it until the fixing procedures are over. Three screw anchors can be used as an alternative to the above-mentioned extensible bar in case of extremely high ceilings or whenever the box has to be embedded into a vertical wall. The box can thus be temporarily fixed to the ceiling/wall by means of its special

"G" slots in the arms. Even if the overall features of both the built-in box and the installation tool herewith described remain basically the same, possible changes or variations can be eventually introduced since they could prove to be necessary to particular processing requirements (moulding, etc.).

Claims

1) "UNIVERSAL BUILT-IN SPOTLIGHT SUPPORT BOX AND RELATIVE FITTING TOOL" characterised principally in that the built-in support box, made in insulating, fire retardant material like the casings for electrical power sockets, can be adapted to the diameter of spotlights by means of horizontal cutting which reduces the length at the lower end, the basic shape of which tapers upwards in a sequence of rings or circular steps. These rings are concentric and of increasing diameter towards the top, externally forming an equal number of cutting planes to choose from, and internally presenting supports for the two sprung arms of the spotlight on the ring ledges or in the steps that may be provided with one or more pairs of raised teeth positioned diametrically opposite each other in order to engage with the above mentioned sprung arms.

2) "BUILT-IN SUPPORT BOX", as in the previous claim, characterised by being composed of a main body and a cover.

3) "BUILT-IN SUPPORT BOX", as in the previous claim, characterised in that, in the main body and/or in the cover, fracture zones are provided, the removal of which allows, in certain cases the passage of sleeves for electrical wires, and in other cases the dispersion of heat.

4) "BUILT-IN SUPPORT BOX", as in the previous claim, characterised in that the main body, open at the two ends, the lower of which is intended for the insertion of a spotlight after adaptation to the diameter of the latter, while the upper opening is intended for the application of a cover, and shaped so as to taper upwards also in the upper part to allow the stacking of elements and the reduction of overall dimensions during storage and transport.

5) "BUILT-IN SUPPORT BOX", as in the previous claims, characterised in that the box volume varies according to the different levels of cover positioning.

6) "BUILT-IN SUPPORT BOX", as in the previous claims, characterised by fact that in can be reduced also in its upper part by cutting it along the "C" line in order to install the cover into an even smaller volume (Fig. 1).

7) "BUILT-IN SUPPORT BOX', as in the previous claims, characterised in that the cover, of whatever shape, is provided with a central stick "F" and two ridges "E" that extend from the cover in diametrically opposite positions allowing the attachment of said cover and the subsequent screwing of the box by the tool that keeping it solidly in place while it is being fixed with cement mortar or other means.

8) "BUILT-IN SUPPORT BOX', as claim 7), characterised in that a pair of elongations "E" extending on the lower side of the cover defines the coupling member of the body "M" of the tool which, used for screwing and fixing in position of the box, can be removed, after the fixing of the box in the masonry, without a reverse screwing movement in relation to the conducted for attachment.

9) "BUILT-IN SUPPORT BOX', as in the previous claims, characterised in that (Fig. 1 - 2 - 3 - 4) with a plan shape essentially circular in its lower part and formed from a sequence of rings of increasing diameter from among which the most suitable is chosen for the insertion of the spotlight, in the upper part, again tapering upwards, there is a lateral enlargement with two section "P" which, diametrically opposite, allow a wider and more effective spreading of the sprung arms "S" of the spotlight.

10) "BUILT-IN SUPPORT BOX", as claim 9), characterised in that, in order to facilitate the removal of the part underlying the ring chosen for the insertion of the spotlight, the connection in sequence of the rings "A" is by means of fracture lines consisting of short thickened sections alternating with openings and extensions, the latter preferable towards the outside so as not to alter the perfect circularity of the seat into which the spotlight is inserted.

11) "UNIVERSAL BUILT-IN SPOTLIGHT SUPPORT BOX AND RELATIVE FITTING TOOL", characterised in that the tool for fitting the above mentioned box (Fig. 11 - 12 - 13- 14), made in such a way as to achieve the screwing of the same and to maintain it solidly in position during fixing with cement mortar or otherwise within a ceiling or wall, consists essentially of two reciprocally locking elements, acting, in opposite directions, one against the lower open base of the box and the other against the cover of the same.

12) "TOOL FOR FITTING THE BUILT-IN SUPPORT BOX", as in claim 11), characterised in that the "L" element acts against the lower edge of the box with a flat section "L" lower in relation to the three arms "I" that extend from this to bear on the masonry structure "O" after formation of the cavity intended to house the box and fixing material "P" of the same (cement mortar, expanding resins, or otherwise). The difference in height between portion "L" and the arms "I" allows the fixture to extend from the box sufficiently to mould, at the same level, the plaster "Q" against which the frame "R" of the spotlight will bear, held in place by the force of the two sprung arms.

13) "TOOL FOR FITTING THE BUILT-IN SUPPORT BOX", as claim 11) and 12), characterised in that on element three arm star-shaped, centred and perpendicular to the flat section "L", there is a cylindrical collar "T" extending to both sides with, on the part opposite the flat section "L", a locking dowel or wing nut "U" used to lock the removable rod "N" provided, at the upper end, with an organ "M" which, intended to act against the cover of the box, allows the insertion of organ "M" pierced in the relative stick "F" of the cover, ensures the engagement of the cover tangs "E" upon the rotation of "M" which are stopped in the fixing position.

14) "TOOL FOR FITTING THE BUILT-IN SUPPORT BOX", as claims 11), 12), and 13), characterised in that when built-in support box has to be inserted into a ceiling, the removable rod "N", suitably prepared at the lower end, is fitted to an extending rod of known type in order to exert pressure between the floor and ceiling and so to support element "L" for the time necessary for fixing the box. In the case of particularly high ceilings, or when the built-in support box has to be fitted in a vertical wall, as an alternative to the above mentioned extending rod, the use of three expansion bolts is foreseen for the temporary fixing of element "L" to the masonry through the relevant slots "G" provided in the arms.

15) "UNIVERSAL BUILT-IN SPOTLIGHT SUPPORT BOX AND RELATIVE FITTING TOOL", as in all the above claims, substantially as illustrated and described for the purposes specified, and independent of such modifications or variations which, without extending beyond the range of the present patent, in practice could prove necessary for particular requirements of moulding or otherwise.

16) "UNIVERSAL BUILT-IN SPOTLIGHT SUPPORT BOX AND RELATIVE FITTING TOOL", as it has been previously stated, explained and described, the universal built-in box and its specific tool for installation can be used to install any kind of equipment (electric, electronic, etc) either into ceilings or into walls. WO 00/31466 AMENDED CLAIMS PCT/IT99/00370

[received by the International Bureau on 28 March 2000 (28.03.00); original claims 3, 11 and 15-16 cancelled; original claims 1,4-10 and 12-14 replaced by new claims 1 and 3-12; remaining claim unchanged (3 pages)]

1) "UNIVERSAL BUILT-IN SPOTLIGHT SUPPORT BOX AND RELATIVE FITTING TOOL" characterised principally in that the built-in support box, can be adapted to the diameter of spotlights by means of horizontal cutting which reduces the length at the lower end, the basic shape of which tapers upwards in a sequence of rings or circular steps. These rings are concentric and of increasing diameter towards the top, externally forming an equal number of cutting planes to choose from.

3) "BUILT-IN SUPPORT BOX", as in the previous claim, characterised in that the main body, open at the two ends, the lower of which is intended for the insertion of a spotlight after adaptation to the diameter of the latter, while the upper opening is intended for the application of a cover, and shaped so as to taper upwards also in the upper part to allow the stacking of elements and the reduction of overall dimensions during storage and transport.

4) "BUILT-IN SUPPORT BOX', as in the previous claims, characterised in that the box volume varies according to the different levels of cover positioning.

5) "BUILT-IN SUPPORT BOX", as in the previous claims, characterised by fact that in can be reduced also in its upper part by cutting it along the "C" line in order to install the cover into an even smaller volume (Fig. 1).

6) "BUILT-IN SUPPORT BOX', as in the previous claims, characterised in that the cover, of whatever shape, is provided with a central stick "F" and two ridges "E" that extend from the cover in diametrically opposite positions allowing the attachment of said cover and the subsequent screwing of the box by the tool that keeping it solidly in place while it is being fixed with cement mortar or other means.

7) "BUILT-IN SUPPORT BOX', as claim 7), characterised in that a pair of elongations "E" extending on the lower side of the cover defines the coupling member of the body "M" of the tool which, used for screwing and fixing in position of the box, can be removed, after the fixing of the box in the masonry, without a reverse screwing movement in relation to the conducted for attachment. 8) "BUILT-IN SUPPORT BOX", as in the previous claims, characterised in that (Fig. 1 - 2 - 3 - 4) with a plan shape essentially circular in its lower part and formed from a sequence of rings of increasing diameter from among which the most suitable is chosen for the insertion of the spotlight, in the upper part, again tapering upwards, there is a lateral enlargement with two section "P" which, diametrically opposite, allow a wider and more effective spreading of the sprung arms "S" of the spotlight.

9) "BUILT-IN SUPPORT BOX', as claim 9), characterised in that, in order to facilitate the removal of the part underlying the ring chosen for the insertion of the spotlight, the connection in sequence of the rings "A" is by means of fracture lines consisting of short thickened sections alternating with openings and extensions, the latter preferable towards the outside so as not to alter the perfect circularity of the seat into which the spotlight is inserted.

10) "TOOL FOR FITTING THE BUILT-IN SUPPORT BOX", as in claim 11), characterised in that the "L" element acts against the lower edge of the box with a flat section "L" lower in relation to the three arms "I" that extend from this to bear on the masonry structure "O" after formation of the cavity intended to house the box and fixing material "P" of the same (cement mortar, expanding resins, or otherwise). The difference in height between portion "L" and the arms "I" allows the fixture to extend from the box sufficiently to mould, at the same level, the plaster "Q" against which the frame "R" of the spotlight will bear, held in place by the force of the two sprung arms.

11) "TOOL FOR FITTING THE BUILT-IN SUPPORT BOX', as claim 11) and 12), characterised in that on element three arm star-shaped, centred and perpendicular to the flat section "L", there is a cylindrical collar "T" extending to both sides with, on the part opposite the flat section "L", a locking dowel or wing nut "U" used to lock the removable rod "N" provided, at the upper end, with an organ "M' which, intended to act against the cover of the box, allows the insertion of organ "M' pierced in the relative stick "F" of the cover, ensures the engagement of the cover tangs "E" upon the rotation of "M' which are stopped in the fixing position.

12) "TOOL FOR FITTING THE BUILT-IN SUPPORT BOX", as claims 11), 12), and 13), characterised in that when built-in support box has to be inserted into a ceiling, the removable rod "N", suitably prepared at the lower end, is fitted to an extending rod of known type in order to exert pressure between the floor and ceiling and so to support element "L" for the time necessary for fixing the box. In the case of particularly high ceilings, or when the built-in support box has to be fitted in a vertical wall, as an alternative to the above mentioned extending rod, the use of three expansion bolts is foreseen for the temporary fixing of element "L" to the masonry through the relevant slots "G" provided in the arms.

11 AMENDED SHEET (ART/CLE 1 9)