EP2581645B1

EP2581645B1 - Modular spotlight

Info

Publication number: EP2581645B1
Application number: EP12188508.1A
Authority: EP
Inventors: Torben Dahl
Original assignee: Daxtor ApS
Current assignee: Daxtor ApS
Priority date: 2011-10-13
Filing date: 2012-10-15
Publication date: 2014-08-27
Anticipated expiration: 2032-10-15
Also published as: EP2581645A1

Description

Field of the Invention

The present invention concerns a number of components or parts forming part of a modular recessed spot system.

Background of the Invention

Typically, a recessed spot, also called an insert, consists of a cylindrical box with an end piece and mounting devices arranged for fastening the recessed spot. To this is added an ornamental ring for covering the recessed spot in relation to the surrounding ceiling or covering.
There are a large number of different types of spotlights which vary due to different kinds of light sources, applications and designs, e.g. so that the light source can be turned in relation to the cylindrical box. Besides, various other equipment such as diverse electronics for controlling light sources, temperature, voltage, current and the like may be installed.
WO 2009/080046 Al , of the same applicant, disclose a mounting device for recessed spots comprising an expansion module with a circular skirt with slots distributed on the periphery and with fastening means, and a fastening module and a cover module.
EP2180240 disclose a lamp aperture holder comprising a substantially tubular main body having a flexible section. A flange is provided integral with said body for supporting said holder when fitted in a lamp aperture. The body being biased towards the lamp aperture by the flexible nature of the body.
US 5,031,084 disclose an adjustable mounting frame for mounting recessed lighting fixtures. The mounting frame includes a mounting ring and spring members which can hold a lighting fixture trim, i.e. housing in place.
The mentioned large variation in recessed spots for many different purposes entails that a large number of recessed spots are to be kept in stock so that a recessed spot with the desired properties can be delivered quickly, and that the installer has to be informed of the frequently very different methods and means for installing the many different types of spotlights. In the production of recessed spots, this furthermore requires many different routines with regard to adjustment of the machines for making the individual components and just as much in connection with mounting where the different recessed spots often require different and varying mounting procedures that may entail errors and lower quality.

Object of the Invention

It is thus the purpose of the present invention to provide a kit of modular parts for a recessed spot from which a great variety of recessed spots with very different properties can be built from standard modules.
Furthermore, there is described a fastening module, in the following also called a locking ring, which can be adapted to different types of recessed spots and/or recessed boxes. The locking ring is characterised in that the locking ring can be used as fastening module for recessed lighting spots or recessed boxes for lighting spots, wherein the locking ring includes an annular main part, and wherein in the main part an expansion element is provided such that the circumference of the annular part can be adjusted so that the diameter can be reduced or increased, wherein the annular main part includes an inner side and an outer side, and wherein the outer side is provided with a groove.
The advantages described above with reference to the fastening module also apply to the locking ring. However, the locking ring is usable for mounting very different elements in a plate-shaped item.
As the invention is directed to a kit of parts for the purpose of supplying various parts which may be mutually assembled to a finished recessed spot, it is clear that the kit comprises multiple different parts, such as a plurality of fastening modules, plurality of expansion modules etc. In this manner it is possible to select suitable parts from the plurality of parts of each type in order to, from standard parts, assemble a recessed spot having special requirements.
In a further preferred embodiment, the locking ring is further characterised in that the locking ring constitutes a plane and that in the locking ring two or more linearly displaceable fastening members are arranged at right angles to the plane of the locking ring, the members capable of being pivoted about the linearly displaceable part, and wherein each member has a part which can be brought to project beyond the outer diameter of the ring. Hereby is enabled a very exact and secure mounting. As the recessed box is arranged in a hole in a building element by means of the locking ring where the hole has a minimum size and the fastening members can be pivoted beyond the plane of the locking ring (and the plane of the mounting box as well), and where the linear movement of the fastening members can be controlled from within the recessed box or the locking ring, a very secure mounting is thus ensured as opposed to the well-know spring devices that imply a substantial uncertainty in connection with what they bear against (wires, insulation, or other) as well as the securing force can be unambiguously determined by the linearly displaceable members.

Description of the Invention

The invention provides for this purpose by a modular kit of parts for a recessed spot, the kit comprising:

a) a plurality of expansion modules, wherein each module is made with a cylindrical skirt portion with a lower edge, wherein at the lower edge there are provided a number of slots in the longitudinal direction of the cylinder distributed on the periphery, and wherein the edge opposite the lower edge is provided with fastening means;
b) a fastening module with an outer circumference and an inner circumference, wherein the outer circumference largely corresponds to an inner circumference of the cylindrical skirt portion on the expansion module, and wherein the fastening module has means for stepless extension of at least the outer circumference and fastening means at the inner circumference for fastening
c) one or more cover modules, wherein means are provided in the cover module for mounting a light source or a complete downlight; wherein the fastening module can be fitted internally of the expansion module and opposite the slots.

By providing a modular recessed spot system, also called an insert, in this way, it will be possible to assemble spotlights for many different purposes with uniform assembling methods and with more different light sources without this entailing variation in the mounting itself of the recessed spots, as well as the fastening of the recessed spots in building or furniture elements can be performed in the same well-known way.
The standardised method, in particular by mounting the individual components and parts in the recessed spot, furthermore enables use of robots entirely or partially in connection with assembling the individual recessed spots.
In a further preferred embodiment, the system additionally includes

d) a plurality of rear pieces wherein the rear pieces in
e) a mounting module for mounting and securing electric components;

A recessed spot will typically have a largely symmetric centre axis corresponding with the direction in which the light is emitted from the spotlight. The rear pieces may vary in length in longitudinal direction of the axis such that the rear pieces can be shaped as lids, i.e. their extension along the longitudinal axis is very limited, or they may have different determined modular dimensions such that the length of the rear piece along the longitudinal axis can be 30, 60, 110, 50 mm, etc.
Correspondingly, the mounting module is designed such that the wire passage is disposed at the same location relative to the means for fastening the electric components which in a mounting situation will make it relatively simple to mount the desired components. In that connection it is furthermore possible to preassemble the mounting module with the electric and electronic components needed with regard to the operation of the intended recessed spot and completely independently of the rear piece which e.g. can be mounted a long time after the mounting module having been mounted. Due to the way of mounting of the parts by clicking it will be possible at any time to click the wanted components together for building up the desired recessed spot from the kit of parts forming part of the recessed spot modular system.
In a further preferred embodiment of the invention, the modular kit of parts is further extended so that the kit of parts further includes an arm which is provided with one or more hinged segments or another form of flexible and bendable members, wherein the mounting module an inner side and an outer side, wherein at the outer side there is provided means for releasable fastening of the arm or another form of flexible member, and wherein the arm or the flexible member projects largely at right angles from the outer side.
The hinged arm enables more space-consuming elements, such as e.g. transformers, terminals, wire reliefs, various electronics etc., to be mounted on the arm, and that the hinged or secured flexible members enable that these components can be inserted in the mounting hole before the recessed spot itself so that the opening to be provided in the recessed part in order to secure the spotlight does not have to be larger than the circumference of the spot itself.
Furthermore, by providing the mounting module with fastening means for the hinged arm or the flexible member as in the case the electric components described above it may be preassembled, and in addition the mounting procedure is well-known as the hinged arm/member and the means for fastening the hinged arm or the flexible member at the outer side of the mounting module are well-known and standard for every one of the recessed spots that can be composed by the kit of parts in the recessed spot system.
In a further preferred embodiment, the modular kit of parts contain a mounting module in which is provided a flexible wire lead-in, preferably designed as a cutout in the wall of the mounting module or at the top of the module with subsequent insertion of a flexible wire lead-in. By designing the cutout in the mounting module in this way it is enabled that a plurality of different wire dimensions with a plurality of different wire lead-ins can be premounted in the mounting module, consequently not changing the mounting module but only the wire dimension with associated wire lead-in. Typically, the wire lead-in will be a flexible plastic/rubber part which can be releasably fastened to the mounting module and fit tightly around the wire. Thus there will be different wire lead-ins for different types of wire with the common feature that they all will have the same outer dimension such that they can be fitted in uniformly in the mounting module or at the top of the module.
In a further preferred embodiment of the invention there is mounted a ventilator in the mounting module and/or in connection with the rear piece. The ventilator is provided such that it can produce an airflow past the light source and thereby cool the light source. Particularly with light sources of the LED type it is important to keep the temperature within a certain interval since the LED light source has optimal light emission in relation to the energy consumption at the correct operating temperature and in addition the light source has a considerably longer service life. For other types of light sources such as halogen it may also be expedient to install a ventilator, not so much for keeping the light source temperate but so as to utilise the waste heat produced by the light source, e.g. for heating the room in which the recessed spot is located.
Finally, the ventilator can create an airflow, both from outside and in and from inside and out, depending on the desired effect. For example, in cases where it is desired to remove the heat from a room, the ventilator may advantageously be set to suck such that the air inside the room is sucked past the light source, thereby cooling the exhausted air which is then discharged at the back side of the building element.
The ventilator may advantageously be mounted with varying distance from the light source such that the ventilator can either be mounted directly in the mounting module or can be arranged via an intermediate piece at a given distance from the mounting module in the same way as the rear pieces.

Description of the Drawing

Figs. 1 and 2: illustrate exploded views of two embodiments of the recessed spot;
Fig. 3: illustrates a section through a recessed spot;
Figs. 4 and 6: illustrate sections through additional embodiments;
Fig. 5: illustrates further details regarding mounting;
Fig. 7: illustrates locking ring with fastening members.

Detailed Description of Embodiments of the Invention

In the following description, the same designations will refer to the same components.
In Figs. 1 and 2 are illustrated the various parts which together constitute a modular kit of parts for a recessed spot. In Fig. 1 is shown a recessed spot which after assembling will have a height of 60 mm, and in Fig. 2 is shown a recessed spot which after assembling will have a height of 110 mm. In both Fig. 1 and Fig. 2 the recessed spot is shown in so-called exploded view where the individual components clearly appear. Both of the recessed spots consist of a rear piece 1, a mounting module 2, an expansion module 3, a fastening module 4 and a cover 5, respectively. In the shown embodiments, the recessed spot is furthermore provided with an arm 6 which by means of a double hinge 7, 8 is releasably fastened to the mounting module 2 in an envelope-shaped holder 9. Moreover, a wire holder 10 is indicated in the mounting module. The wire holder 10 is usually designed in a rubber-like material such that the outer dimensions are uniform whereas the aperture provided in the wire holder varies according to the type of wire used for leading electricity to the light source mounted in the recessed spot.
In the shown examples a box 11 is provided on the hinged arm 6, in which box 11 there may be located a transformer, a wire holder/relief, connecting terminal which is shown with reference to Fig. 4, or other equipment for the recessed spot.
In Fig. 2 is shown an insert for a recessed spot with a height of 110 mm. The feature causing the changed built-in height is the extension of the rear piece 1 in the longitudinal axis 20 of the recessed spot. As it appears from Fig. 2, all other parts, i.e. the mounting module 2, the expansion module 3, the fastening module 4 and the cover 5 are identical to the corresponding modules depicted in Fig. 1. In that way it is thus possible with standard components to provide a large number of recessed spots with varying dimensions from the kit of parts which is part of the invention.
The cover 5 may of course be made with different designs, colours, materials etc. such that the part of the recessed spot becoming visible after mounting fits into the environment into which the recessed spot is built.
The insert consisting of the parts described above are mounted in an opening in a building element by inserting the insert from below, and when the flaps 3' of the expansion module are outside the building element, e.g. a ceiling sheet, a plywood sheet or similar, the fastening module 4 is actuated such that the diameter of the fastening module is made larger whereby the flaps 3' are bent outwards relative to the longitudinal axis 20, engaging the surrounding opening in the building element. The insert is hereby fastened in relation the building element. Finally, the cover 5 is mounted in that the bayonet socket 12 provided in the mounting end of the cover 5 is pushed in and turned relative to pins 13 in the fastening module.
A cross-section through an insert according to the invention is indicated with reference to Fig. 3. The insert includes a rear piece 1 which is clicked into the mounting module 2. In connection with clicking the individual parts belonging to the system together, advantageously an O-ring 15 can be inserted, in particular in the joints between the rear piece and the mounting module and the expansion module, respectively, such that tightness is achieved. Tightness is important as modem buildings are to be made such as to pass a tightness test, i.e. leaks causing loss of heat and the like must not exist, and by making the recessed spot in this way with a largely airtight housing it is ensured that it is not the recessed spot as such that gives rise to leaks, thereby causing the construction not to fulfil the requirements for tightness. Furthermore, an O-ring in the click joint between the above mentions modules will act as a resilient clamping such that the individual parts are secured in a better way.
The mounting module 2 is also clicked to the expansion module 3. The fastening module has an outer diameter such that as illustrated in Fig. 3 it can be disposed internally of a lower part of the expansion module opposite the flaps of the expansion module. Hereby it is ensured that when the diameter of the fastening module is enlarged, the flaps will be pressed outwards and go against the surrounding building element, thereby fixing the recessed spot in relation to the building element. In Fig. 3, the surface 15 of the building element is marked as being flush with the back side of the cover 5 such that a tightly fitting mounting of the recessed spot relative to the building element 15 is achieved. At the back side of the building element, the arm 6 is designed with a curving part 16 such that the arm can be displaced at the back side of the building element 15 during and after mounting and due to the rounding slide across possible irregularities, such as joints between elements of which the building element 15 may be made up of, wires lying loosely on the ceiling sheet or other obstacles that may prevent the arm 6 from coming into contact with the back side of the building element 15. In that the arm 6 bears on the back side of the building element 15, the recessed spot is relieved due to the two pivotable hinges 7, 8, and thereby the fastening itself against the building element by means of the fastening module is relieved and not subjected to eccentric load so that a long-term and durable fastening is achieved without unfavourable eccentric load.
The fastening module includes an expansion element which by turning the screw 17 causes the diameter to be reduced or increased, respectively. The screw 17 can be actuated from the interior of the recessed spot such that fastening of the recessed spot can be effected expediently via the interior of the recessed spot after being passed up through a hole in the building element 15.
In Fig. 4 is illustrated a cross-section through yet an embodiment of the invention where a wire relief/terminal 38 is provided on the arm 6, covered by the box 11. Correspondingly, at the end side 11 of the box there is provided a lead-in 11' such that the live wire for supplying the recessed spot with energy can be mounted in the terminal 38. In addition, this means that the recessed spot can be preassembled, i.e. light source with electric connection to the terminal possibly with LED driver or transformer can be preassembled industrially such that the electric wire conducting current to the light source is only to be connected in the terminal in connection with onsite installation of the recessed spot.
By this version there is provided a V-shaped groove 18 in the fastening module 4, which groove 18 is used for receiving pins 21, see Fig. 5. The pins are used for mechanically fixing the fastening module in relation to the expansion module whereby the light source (not shown) can be turned in relation to the position of the recessed box in the building element in order to attain a possible desired direction of the light emission.
Turning back to Fig. 4, there is furthermore shown a packing 19 which corresponding to the above mentioned O-rings is to provide the wanted tightness between the rear edge of the recessed box, i.e. the edge 4" abutting on the cover 5, whereby tightness is achieved here as well.
In Fig. 5 is finally shown a relatively low recessed spot corresponding to the recessed spot in Fig. 1 wherein, as already mentioned above, fixing pins 21 have been provided for fixing the fastening module 4 relative to the expansion module 3.
In fig. 6 is illustrated a further embodiment of the invention wherein a ventilation module 25 including a ventilator 26 is provided. The ventilation module 25 is mounted in the same way as the rear piece 1, i.e. by being attached on the mounting module by clicking. The ventilation module 25 consists of a rear piece 27 that fits tightly against the mounting module such that a largely airtight joint is achieved between the rear piece 27 and the mounting module 2. The ventilator 26 is supplied with energy via the wire connected to the terminal 38, see Fig. 4.
In a further embodiment, the ventilation module 25 can be designed with a plug so that when the ventilation module 25 is inserted in the mounting module 2, the plug can be inserted into a corresponding socket provided in a component mounted in the box 11 on the arm 6 in a corresponding way. The mounting of the ventilation module 25 is hereby facilitated and expedited.
In Fig. 1, the arm 6 is shown mounted on the mounting module 2 by means of the envelope holder 9. In Fig. 6, the ventilation module 25 is shown mounted partly on the holder 9 for the arm 6 and partly on a further holder 9'. In contrast to the holder 9 in Fig. 1 where it is mounted in the mounting module 2, the holders 9, 9' are here mounted at an upper part of the expansion module 3 by means of screw connections 31. In embodiments of the invention in which holders or other means are not to be fitted, blanking off pieces are placed instead of the holders 9, 9'.
The ventilator module 25 can be arranged at varying levels as the releasable fastening of the ventilator module is squeezed around the arm 29 (part of the holder 9'). Hereby, ventilation for different types and sizes of light sources can be allowed for.
The ventilator module can either be designed as closed, i.e. when mounted on the mounting module 2 a largely airtight assembly is created as described above, or the module may have one or more ventilation slots so that cooling air can be exhausted above the ceiling or air from above the ceiling can be passed down past the light source.
The fastening module/locking ring 4 is illustrated in Fig. 7. The locking ring forms an X-Z plane. In the Y direction, at right angles to this plane, two linearly displaceable fastening members 30, 31 are arranged. In the shown embodiment, each member is designed as a bolt with a head 32, 33 and a shank 34, 35 provided with a screw thread. In the locking ring, holes with corresponding screw threads are provided such that by turning the head 32, 33 the fastening members 30, 31 can be moved linearly closer to or farther from the plane X-Z of the locking ring. On the fastening members 30, 31 there is furthermore provided projecting parts 36, 37. These parts 36, 37 can be pivoted about the linear fastening legs such that the part can be brought outside the outer periphery of the locking ring. When by manipulation of the linear fastening members the parts 36, 37 then are displaced linearly up/down relative to the X-Z plane, the parts 36, 37 can be brought into contact with the building or furniture element in which the locking ring is to be mounted.

Claims

Modular kit of parts for recessed spots, the kit comprising:
a) a plurality of expansion modules (3), wherein each module (3) is made with a cylindrical skirt portion with a lower edge, wherein at the lower edge there are provided a number of slots in the longitudinal direction of the cylinder distributed on the periphery, and wherein the edge opposite the lower edge is provided with fastening means;

b) a fastening module (4) with an outer circumference and an inner circumference, wherein the outer circumference largely corresponds to an inner circumference of the cylindrical skirt portion on the expansion module (3), and wherein the fastening module (4) has means for stepless extension of at least the outer circumference and fastening means at the inner circumference for fastening

c) one or more cover modules (5), wherein means are provided in the cover module (5) for mounting a light source or a complete downlight;
wherein the fastening module (4) can be fitted internally in the expansion module (3) opposite the slots.
Modular kit of parts for a recessed spot according to claim 1, wherein the kit further comprises
d) a plurality of rear pieces (1) wherein the rear pieces (1) are mounted in

e) a mounting module (2) for mounting and securing electric components (11);
in which each of the rear pieces (1) can be clicked into engagement with the mounting module (2) and any of the expansion modules (3) can be clicked into engagement with the mounting module (2).
Modular kit of parts for a recessed spot according to claim 1 or 2, characterised in that the kit of parts further includes an arm (6), which arm (6) is provided with one or more hinged members (7,8), wherein the expansion module (3) in the upper part has means (9) for releasable fastening of the arm (6), or wherein the mounting module (2) has an inner side and an outer side, wherein on the outer side there is provided means (9) for releasable fastening of the arm (6), and wherein the arm (6) projects largely at right angles from the outer side of the recessed spot.
Modular kit of parts for a recessed spot according to claim 1, characterised in that the mounting module (2) includes a flexible wire lead-in (11'), preferably designed as a cutout in the wall of the mounting module (2) with subsequent insertion of a flexible wire lead-in (11').
Modular kit of parts for a recessed spot according to claim 1 or 2, characterised in that means are arranged in the expansion module (3) or mounting module (2) for adjustable mounting of a ventilator module (25), including a rear box (27) and a ventilator (26), wherein the rear box (27) contains means (38) for electric connection to the ventilator (26) and to an energy source.
Modular kit of parts for a recessed spot according to claim 5, characterised in that the ventilator module (25) between the ventilator (26) and the rear box (27) forms a venting gap through which air can be sucked into and blown out from the recessed spot, respectively.
Modular kit of parts for a recessed spot according to claim 3, characterised in that one or more electric components (11) are arranged on the arm (6), wherein the electric components (11) may include a transformer, electric connection terminal, electronic control of light source, driver for LED light source, or other relevant equipment.
Locking ring capable of being used as fastening module (4) for recessed lighting spots or recessed boxes for lighting spots, wherein the locking ring (4) includes an annular main part, characterised in that in the main part an expansion element is provided such that the circumference of the annular part can be adjusted so that the diameter can be reduced or increased, wherein the annular main part includes an inner side and an outer side, and wherein the outer side is provided with a groove (18) and wherein the locking ring (4) constitutes a plane and that in the locking ring (4) two or more linearly displaceable fastening members (30,31) are arranged at right angles to the plane of the locking ring, the members (30,31) capable of being pivoted about the linearly displaceable part (30,31), and wherein each member has a part (37) which can be brought to project beyond the outer diameter of the ring (4).