Selectively extendable modular lighting fixture, and method of making and assembly

A lighting fixture which includes an elongate modular lineal section fabricated of an extruded high-strencth metal alloy. The extrusion comprises an elongate generally flat base integrally joined at a pair of opposed lingitudinal edges thereof to upwardly extending sidewalls. The sidewalls are formed at opposed respective upper edge portions thereof with channel-like upwardly opening grooves for matingly receiving therewithin laterally spaced elongate free edge portions of a lens of a high strength plastics composition. The lens bridges opposed sidewalls of the extruded metal base to complete a lighting fixture housing section or module open at each end. Configured for matingly engaging and for positive attachment to each end of the housing section is a skeletal bridge-like end plate formed with through framed openings. Attachable to each or to either end plate is a skeletal adapter ring for facilitating attachment of an additional housing section or module to provide a lighting fixture comprised of two or more modular housing sections. End caps provide fluid-tight closures of the assembly. In other embodiments of the invention the modular structures may be connected to provide lighting fixtures which form L, T, cross, X, as well as closed-loop configurations.

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Description
FIELD AND BACKGROUND OF THE INVENTION

[0001] The present invention relates to a lighting fixture. More particularly, the invention is directed to an elongate modular, lineally-extending light fixture for ceiling, wall, corner and row-mount mounting, and to the method of fabrication of such a fixture.

[0002] Many different types of lighting fixtures, including elongate fixtures for various applications and locations are known in the art. Such fixtures have been installed for general illumination in stores, offices, supermarkets, schools, hospitals, banks and other interior and outside areas. Appreciating the versatility of such lighting fixtures, including the many engineering designs and configurations heretofore devised and adopted, there appears still to remain a real need for still another versatile, specially-adaptable lighting fixture to facilitate and enhance particular applications.

[0003] It is a particular aim of the present invention to provide an exceedingly simple yet readily-adaptable and adjustable such lighting fixture. The present invention is offered to provide a high-quality lighting fixture to meet and to fulfill a perceived need—a need believed not heretofore to have been completely appreciated or fully satisfied.

[0004] The need referred to is of a lighting fixture of readily adjustable length and physical configuration, and adaptable fully to traverse and completely to fill any required or desired lineal as well as areal expanse. The present invention effectively meets the challanges posed—and in an artistically pleasing mode, while obviating shortcomings and inadequacies of prior art lighting fixtures. Thus, principal realized aims of the present invention are to confront, to meet and to eliminate such inadquacies and shortcomings, and to provide simple yet remarkably effective solutions to the problems posed.

SUMMARY OF THE INVENTION

[0005] In a “descriptive” sense the lighting fixture of the present invention may be characterized as “selectably extendable and angularly directable “linear” lighting”. It is a critical feature of the present invention that it constitutes one or more generally tubular “modules”, sections, or housing components, these being joined to one another at end portions or segments thereof. The structure thus produced constitutes, in a principal embodiment thereof, a lineal array, of selectable length or lineal expanse—as required or desired. Alternatively, lineal sectors or sections of the lighting fixture may be oriented with respect to one another to provide various different “geometric” configurations or shapes. These accommodate direction change modes or related needs.

[0006] Among these optional configurations is an essentially in lineal or straight line array of any desired expanse. Alternatively, the fixture may consist of two lineal arrays connected at ends thereof to define a 90 degree juncture or corner. Also, through the use of yet another special connector, three linear arrays of the modules of the fixture may be connected to form a T node or configuration. In yet another physical arrangement, a specially designed cross-connector or coupler is provided to define and constitute a joinder structure in which four separate and distinct lineal sectors of a fixture are interconnected or functionally joined as an X type mode to extend at 90 degrees to one another.

[0007] An important structural feature of the invention is that the modular sections include extrusions constituting high-strength metal alloys such as aluminum alloys. The extrusions define a principal support element of each housing section or module. In a preferred embodiment of the invention the metal extrusion takes the physical form of an elongate, generally flat base integrally joined at a pair of opposed longitudinal edges thereof to upwardly-directed sidewalls.

[0008] In a preferred embodiment of the invention the sidewalls of the extrusion are—or the side walls of each extrusion are—integrally formed at opposed respective upper elongate edge portions thereof with channel-like upwardly opening grooves or slots. These serve matingly to receive therewithin laterally-spaced elongate free edge portions of a lens of a high-strength plastics composition.

[0009] It is an important feature of the invention that there are provided gaskets, which include die-cut gaskets, which extend along a lineal expanse of the plastics lens for establishing a fluid-impervious seal. Conveniently, the gasket is seated in an elongate groove formed adjacebt a free edge portions of the lens.

[0010] It is a feature of the invention that the lens, which defines and controls distribution of illuminating light emanating from the fixture, is composed of a high-impact, shock-resistant plastics composition including acrylic plastics and polycarbonate plastics.

[0011] Yet another feature of the configuration of a preferred embodiment of the plastics lens is that it is formed to define along each extending edge thereof with an angled flange for overlying an edge of the coextensive extruded base of the housing or body section.

[0012] It will be understood that the lens, coextensive with the lineally extending extruded metal base, bridges opposed side walls of the extruded metal base to complete a generally tubular lighting fixture housing section which is open at each end. It will be appreciated as well that the metallic extrusion and the lens mounted therealong and sealingly coupled thereto may be of any selectable length or lineal expanse in the fabrication of a specific module, in accordance with the present invention.

[0013] A further important physical component of each elongate modular section of the lighting fixture is an endplate mounted on the housing-like body section coaxially therewith at each end thereof.

[0014] n preferred embodiments of the invention, the end plate constitutes a casting formed of a metallic composition or alloy. The end plate is formed at an inner face thereof with an outwardly opening slot or groove extending along a bounding coextensive edge zone thereof for accepting therewithin, in mating and sealing engagement therewith, the extruded metallic base component of the housing and the surmounting plastics lens thereof.

[0015] It is a very significant feature of the invention that at its opposite sides the end plate is configured to define an end face contoured for mounting thereon and affixing thereto, selectively, either an end cap for capping and closing the housing of the modular structure, or a ring in the form of a band-like coupler. The coupler is configured for sealingly mounting on the end plate of the housing for joining the end of the housing section to an end plate of a second housing body of a second modular housing section of the lighting fixture so that the sections are sealingly joined to one another endwise.

[0016] It will be understood that irrespective of the partucular number of lineally extending, joined modular body sections in a given installation, ends of each fixture terminate in a fixture-secured end cap fastened on a supporting end plate.

[0017] The end cap of a preferred embodiment of the invention is integrally formed with a circumambient, outwardly-projecting, flange-like edge portion configured to overlie, in sealing engagement therewith, a perimetric shoulder circumscribing an outwardly presented face of an end plate attached to the housing.

[0018] It is yet another important structural feature of the cast end plate of the coaxial cast coupler ring that each is skeletal in construction with a plurality of through openings or passageways or runs, commonly called “raceways”. The latter accommodate the passage and extension therethrough of wires and electrical fixture components for traversing the lineal expanse of the modular housings of the lighting fixture, through each end-joined lineal section thereof.

[0019] It is an exceedingly significant capability and attribute of the lighting fixture of the invention that the elongate body or housing may constitute an elongate array of any selectable number of “modules” or body sections, functionally to traverse any given or intended expanse.

[0020] Physically, the individual, end-abutting sectors or housing sections of the lighting fixture of the invention establish therewithin and along an entire expanse thereof uninterrupted passageways. These include raceways for accommodating wires, cables and the like. The latter are effectively isolated from ballasts and lamp wires. It is significant that, in accordance with the practice of the present invention, there are provided physical barriers establishing and effectively separating, two isolated raceways. These are in addition to a passageway for the ballast power feed wires. The described, exceedingly significant and important physical structural arrangement is highly desirable. The structural arrangement and configuration of the fixtures of the present invention, as described, facilitate, effectuate and ensure important and critical physical separation of high voltage and low voltage wiring. The “utility” and versatility of the fixtures of the present invention are thus signifigantly and materially enhanced.

[0021] Among the items (and “features”) which may be safely housed in an “isolated” raceway such as that contained in the fixtures of the present invention are 24-volt alarm circuitry, such as a fire alarm; fibre optic network cables; a thermostat wire; telephone wires; etc. The capabilities outlined above are capabilities provided in the present invention. They are believed to be capabilities unique in lighting fixtures of the ““general type” in which the lighting fixtures of the present invention may customarily be grouped or “classified’.

[0022] Yet another feature of the invention is that although it may be especially advantageous and convenient to fabricate all of the modular body sections of the lighting fixture are all of the same length. Such arbitrary “uniformity” is in no sense a requirement. Conveniently, individual luminaires may be nominally 8″×24″, 8″×48″, or 8″×60″. Other embodiments maybe nominally 12″×24″. 12″×48″. or 12″×60″.

[0023] Other and further objects, features and advantages of the invention will become apparent from the following further description considered with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 is a perspective view of a single, self-contained, and end-capped lineal module of one embodiment of the lighting fixture of the invention;

[0025] FIG. 2 shows two modular sections of the lighting fixture of the invention joined to one another endwise through an interposed coupler ring;

[0026] FIG. 3 is a fragmentary, exploded perspective view of a body section of a lighting fixture of the invention with an end plate affixed in place for attachment to an end cap of the lighting fixture;

[0027] FIG. 4 is a fragmentary, exploded view showing an end of a body section of the fixture with an end plate secured in place for attachment to a separate coupler ring thereto;

[0028] FIG. 5 is an elevational view of an end plate for mounting on an end of the body of a housing section of the lighting fixture of the invention and showing the wall configuration of the end plate;

[0029] FIG. 6 is an elevational view of a coupling ring for securement to the end plate of a housing section or module to be made a part of the lighting fixture of the invention;

[0030] FIG. 7 is a fragmentary perspective view as seen upwardly from the inside of a housing section of the lighting fixture of the invention, and showing an end plate thereof with a coupler ring fastened thereto;

[0031] FIG. 8 is a cross-sectional view taken substantially on the lines 8-8 of FIG. 2, and illustrating one method of securing one housing section or module of the lighting fixture of the invention to another;

[0032] FIG. 9 is a fragmentary, cross-sectional view taken along the lines 9-9 of FIG. 2, with parts omitted for the purpose of clarity;

[0033] FIG. 10 is a schematic plan view of two modular sections of a lighting fixture of the invention joined to one another at right angles by means of an L-configured connecting adapter to form an L-node or “corner mode” assembly, it being understood that through the use of four such L connectors and four modular sections it is a simple adaptation to provide a lighting fixture of the invention in the physical configuration of a closed rectangular “loop”;

[0034] FIG. 11 is a schematic plan view showing three modular sections of a lighting fixture of the present fixture connected to a joinder adapter to configure the lighting fixture as a T node or cross mode; and

[0035] FIG. 12 is a schematic plan view of four modular sections of a lighting fixture according to the present invention, and joined through a rectangular, four-faced, outwardly coupler to form an X node lighting fixture assembly in which the four modular arms extend at 90 degrees to one another.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] In accordance with the present invention, the aims and objects are achieved by providing a lighting fixture comprised of either a single module of selectable length, or alternatively, a plurality of modular sections, sectors, or housing sections joined to one another endwise as a lineal or in-line array. The method is readily effective to provide a lineal lighting fixture of any desired or required expanse. Many other embodiments of the invention are possible. Modular lineal sections maybe coupled at joined ends thereof to extend normally to one another to define a right-angle corner. Others may be connected by means of a T-shaped coupler to form a “T”. Still other modular sectors, of selectable lengths, may be connected to form an “X” or a cross.

[0037] The housing sections themselves, which may be of any practical selectable lengths, each have end plates attached thereto. The end plates are presented to face one another. Finally, the end plates of two linearly adjacent housing sections are brought matingly to engage a lineally interposed coupling ring, thus to effect a sealed joinder of the two adjacent housing modules or housing sections of the lighting fixyure, one to the other.

[0038] Referring now to the drawings, for purposes of disclosure and not in any limiting sense, preferred embodiments of the lighting fixture of the invention are shown in FIGS. 1, 2 and 3 in the form of a fixture 20 constituting a single module or modular housing section or component 24 (in FIG. 1), and a fixture 30 having two modules or housing sections 24 (in FIG. 2). The two housing sections 24 of the Fixture 30, as shown in FIG. 2 are secured to one another endwise at respective facing end plates 34 thereof (FIGS. 3 through 8), by means of a coupler ring 40 (FIGS. 2, 4 and 8) interposed between respective end portions of a pair of identical housing portions or modules 24.

[0039] Each fixture is shown in FIGS. 1 and 2 as securedly mounted at respective generally planar bases 48 thereof to a ceiling structure 50. Free ends of housings 24 are sealed at surmounting end plates 34 thereof with fitted end caps 52. The latter abut and are secured to, to overlie the mounted end plate 34. (FIG. 3). Each housing section 24 of the fixture of the invention includes opposed lineally extending side walls 56 and 58 integrally formed with and extending co-extensively with the bases 48 at elongate upperedges 64 and 66 thereof (FIG. 3).

[0040] Referring further to FIGS. 1 and 2, disposed to extend along and joined at opposed longitudinally extending lower free edges 72 and 74 of the opposed sidewalls 56 and 58 thereof, is an elongate sheet-like lens 80. The lens 80 which bridges between opposed elongate free edges 72 and 74 of the sidewalls 56 and 58 of the housing 24, is integrally formed along a co-extensive lineal expanse thereof with upwardly-directed flanges 86 and 88 to seat within downwaredly-opening elongate grooves or slots 96 and 98 formed in lower free elongate opposed edge zones 104 and 106 of the sidewalls 56 and 58. Also depending from and extending longitudinally along a lineal expanse of the sidewalls 56 and 58 and integrally formed therewith are downwardly projecting plate-like strips 110 and 112. At their free downwardly presented lower edges, the strips 110 and 112 abut, in sealing engagement therewith, laterally outwardly extending plates 114 and 116.

[0041] As shown in FIG. 9, a die cut gasket 120 is interposed sealingly to engage the strips 110 and 112.

[0042] Referring now further to FIGS. 3 through 6, the body of the housing 24 carries at each end thereof, in fixed and secured engagement therewith, an end plate 34 constituting a high-strength casting of a metal composition, preferably a casting composed of a lightweight metal, such as an alloy of aluminum. As shown in FIGS. 3 and 4, the end plate 34 is a unitary structure constituting an integrally-formed, plate-like structure which is skeletal in configuration. The casting 34 has a plurality of through openings or passageways 134, 136, 138 and 140 formed in a generally planar vertically extending body 142 thereof to provide wire ways and to facilitate passage therethrough of lighting tracks, conductive wires, illuminating sources and other electrical components and related structures. Surmounting the end plate 34 is a top flange 148 which extends contiguously and coextensively along a top end edge of the base 48 of the housing 24 in sealing engagement therewith. Integrally formed with and co-extensive with the top flange 48 and stepped downwardly with respect thereto is a second flange 152.

[0043] Referring further to FIG. 3, the end cap 52 is integrally formed with a flange 156 projecting outwardly along a top, free edge 158 thereof. As indicated schematically, when the end cap 52 is positioned in place to mate with and close the end of the housing 24, the top flange 156 of the end cap 52 is brought to overlie and to effect a sealing engagement with the flange 152 of the housing 24. At the same time an arcuate lower flange 162 of the end cap 52 engages and seals with a cooperating lower flange 164 of the end plate 142. The end plate 130 is positively secured to the end of the housing 24 by means of screws 166 and 168.

[0044] As also shown in FIG. 3, the end cap 52 is integrally formed with connector posts 170 and 172 projecting through the lineal expanse of the end cap 52 from the interior of the end wall 176 at opposed upper corners thereof. A third connector post 180, also integrally formed with the end cap 52, also projects inwardly from the interior of the end wall 176 at a central lower zonal area thereof. As depicted schematically in FIG. 3, when the cap 52 is positioned in place, the free ends of the posts 170, 172 and 180 penetrate to seat, respectively, in cooperating outwardly-presented bores 184, 186 and 188 formed in the end plate 34.

[0045] Referring further to FIGS. 3, 4 and 5, the end plate 34 is formed, on the interior of the opposed upper side sectors 190 and 192 thereof and the continuing lower arcuate section 196 thereof, with an uninterrupted channel 200. The chanel 200, which opens outwardly, is contoured, configured and sized for receiving in close and sealing engagement therewithin the opposed edge portions 72 and 74 of the sidewalls 56 and 58 and of the lens 80 of the housing 24.

[0046] Referring to FIGS. 2 and 5-8, embodiments of the lighting fixtures of the invention which include two or more housing sections or modular components 24 joined endwise as a continuous uninterrupted physical structure (FIG. 2) include a coupler or coupler ring 40 (FIG. 4). The latter has generally the contour and form of the end plate 34 of the fixtures and is preferably, as in the end plate 34, also a metal casting of an aluminum alloy. As in the case of the end plate 34, the coupler ring 40 is formed with a plurality of through openings 210, 212, 216 and 218. These openings are essentially congruent with the opening formed in the end plate 34 and in through registry therewith when the end plate 34 and the coupler ring 40 are used together—one with the other in an assembled lighting fixture having a plurality of body sectors or modules 24.

[0047] The coupler ring 40 has a circumscribing body contour which corresponds in material respects to the perimetric contour of the end plate 34, as shown in FIGS. 5 and 6. At a transversly extending generally planar top surface 220 and at a continuing integrally-formed arcuate bottom surface thereof, the coupler ring 40 is integrally formed with a flange-like top wall 220 extending laterally of the body 224 at each of opposed sides thereof effectively to provide two opposed co-extensive over-hanging flanges. The flange-like top wall 220 is operative to overlie in closely contacting engagement therewith a downwardly displaced or stepped co-extensive flange 152 of an end plate 34. The end plate 34 is secured to the body or housing module 24 of the fixture of the invention as previously described. In the manner explained, a second housing component 24 may be fastened, at its secured end plate 34 at the opposite, co-extensive second part of the flange 220 thus to effect a coupling of two housing sections 24 to one another endwise. In the manner described, it becomes simple and quick to produce a row-mount lighting fixture having a selectable number of separate housing sections—each itself being in turn of a selectable length. Thus, one may readily generate a lighting fixture of any final overall length, as may be required or desired.

[0048] Referring now to FIGS. 10, 11, and 12, it is within the purview and scope of the present invention that it includes lighting fixtures which are not limited to extending along or to traverse a straight line only. Rather, other geometric configurations of the lighting fixture have proven feasible and practical. For example, referring first to FIG. 10, there is shown a fragmentary view of a unitary lighting fixture of the invention constituting two modular sections 24 oriented to extend normally to one another. There is provided a generally rectangular connector 230 to a pair of adjacent sides 232 and 234 of which ends 236 and 238 of the modular sections 24 are abuttingly and sealingly joined to form a corner assembly. The resulting fixture, which assumes an L shape, is suited for accommodating sharp bends, and for corner installations.

[0049] A second example of a non-linear embodiment of the fixtures of the present invention is illustrated in FIG. 11. As shown, there is provided a generally rectangular connector 240 to respective three sides 242, 244 and 246 of which three separate modular sections 24 of the fixture are connected. The assembled fixture thus assumes a T configuration.

[0050] Yet another embodiment of the invention is depicted in FIG. 12. As shown, there is provided a four-sided rectangular connector 250 to each side of which an end 252, 254, 256 and 258 of a separate module or fixture section 24 is joined. There results a fixture having a cross or X-like configuration. It will be appreciated that, in accordance with the teachings of the present invention, through the use of appropriate selectable connectors, closed loop lighting fixtures embodying the principles and features of the invention may also be provided.

Claims

1. An extendable modular lighting fixture including means for rendering said fixture functionally operable as a fixture with a single modular section and alternatively as a row-mount lighting fixture having a plurality of modular sections,

said row-mount lighting fixture comprising an array of housing sections joined to ome another endwise;
interconnecting means for providing physical and electrical continuity throughout a lineal expanse of said lighting fixture;
said lighting fixture being further chacterized as being, through structural configuration of components thereof and through composition, inherently effectively tolerant of and resistant to physical abuse as well as to environmental hazards;
said lighting fixture further comprising housing means for carrying therewithin an illumination source to extend interiorly therealong;
a lighting track in said housing means;
said lighting track including passageway means for accommodating electrical conductor means for connecting said lighting fixture to an independent electrical power supply for energizing said lighting fixture;
wire-way means formed within said lighting fixture for accommodating conductive wires residing in said housing means and extending along a lineal expanse thereof;
elongate lens means extending along a lineal expanse of said lighting fixture and secured thereto for defining and controlling distribution of illuminating light emanating from said lighting fixture; and
removable cap means for closing and sealing opposed ends of end units of said lighting fixture.

2 A lighting fixture as set forth in clain 1 and comprising a row-mount configuration and including a plurality of housing means, and wherein each said housing means constitutes a module of said lighting fixture,

each said module of said housing fixture characterized in that corresponding structural components of each are operatively comprised of the same mechanical configeration;
an end plate mounted on each said module at each of opposed ends thereof;
ring-like coupler means for establishing a mechanical joinder of two adjacent said modules to one another endwise at opposed said modules at each said end plate thereof presented to said coupler means, thereby to establish a positive joinder of said modules to one another and to establish a modular row-mount fixture of a selectable lineal expanse.

3. A lighting fixture as set forth in claim 2, and further comprising additional modules connected into said row-mount configuration of said lighting fixture to constitute extensions thereof.

4. A lighting fixture as set forth in claim 1 wherein said lighting fixture includes an elongate extruded skeletal structure defining a body-like lineal support frame for said lighting fixture.

5. A ligfhting fixture as set forth in claim 1 and further comprising gasket means seated and secured in said housing means along an expanse thereof and in sealing engagement for sealing said housing means against invasion by objectional ambient and foreign substances.

6. A lighting fixture as set forth in claim 1 wherein said lens means is of a high impact, shock resistant plastics composition including acrylic plastics and polycarbonate plastics.

7. A lighting fixture as set forth in claim 1 and further comprising an end plate affixed at each of opposed ends of each said module of said lighting fixture, and wherein each said end plate is formed therein with longitudinally extending, inwardly directed groove means for slideably receiving to seat therewithin longitudinally extending marginal end edge portions of said lens means in sealing engagement within said groove means.

8. A lighting fixture as set forth in claim 1 wherein said hoising means is formed along a lineal expanse at opposed upper edge zones thereof with upwardly opening slot-like grooves, and wherein said lens means is formed along opposed longitudinally coextending lower free edge zones thereof with web means for slideably penetrating and seating in said groove in said housing means to esrablish a protective shield between said housing means and said lens means.

9. A lighting fixture as set forth in claim 8 and further comprising flange means carried by said lens means along a lineal expanse thereof for overlying said housing means along a full lineal expanse theeof.

10. A lighting fixture as set forth in claim 1 wherein said lighting fixture is comprised of a single modular section only.

11. A lighting fixture for selective ceiling, wall and corner installation; said fixture comprising an elongate body, and said body defining a lineal expanse including a tubular channel in said body, and coextensive therewith;

said channel comprising elongate, chanber-like spatial means for accommodating an illuminating element within said fixture;
said body of said fixture having an opening at each end thereof, and an elongate passageway open along said lineal expanse of said body and coextensive therewith;
said body defining a housing;
wire raceway means within said housing for accommodating conductive wires to extend longitudinally within said housing along said lineal expanse thereof;
a lens, and means for securing said lens to said body to cover said opening along said lineal expanse of said housing; said lens constituting means for transmittal of illuminating light from said lighting fixture;
an end cap for each end of said lighting fixture, and means for coupling said end cap to said body of said fixture to provide a stable mechanical closure structure therefor.

12. A lighting fixture as set forth in claim 11 wherein said channel includes space means for accommodating a source for illumination for operation functionally within said lighting fixture.

13. A lighting fixture as set forth in claim 11 wherein said body of said fixture includes an extruded section of a metallic composition.

14. A lighting fixture as set forth in claim 11, and further comprising gasket means functionally disposed between said body of said fixture and said lens for establishing a fluid-impervious seal between said body of said fixture and said lens.

15. A lighting fixture as set forth in claim 11 wherein said lens is integrally formed with a flange extending along each of opposed longitudinal edges of said lens, and wherein said means for securing said lens to said body includes upwardly opening slot-like grooves formed in said body of said fixture to extend along a lineal expanse of opposed sidewalls of said body of said fixture to receive each respective said flange of said lens therewithin, and to establish a fluid-impervious seal between said body of said fixture and said lens.

16. A fixture as set forth in claim 1 wherein each said end cap is formed with a circumambient outwardly-presented groove for receiving therewithin in sealing engagement therewith an end portion of said lens, at each end thereof.

17. The method of making and assembling a lighting fixture having any selectable length and finding utility in ceiling, wall and corner installations including suspended mounts;

said method utilizing modular components in selectable numbers, each component being of any desired length, and said components being connectable to one another endwise as a sealed, unitary, operating assemblage constituting a lighting fixture;
said method including the fabrication of a modular component of said fixture, and comprising the steps of:
forming an extrusion having a generally planar floor-like base integrally joined at opposed lateral lineally-extending side edges thereof with generally upwardly projecting wall sections;
forming said wall sections of said extrusions at lineally-extending opposed edge portions thereof with upwardly-directed coupler structures for attaching a lens thereto at opposed said lineally-extending said edge portions of said extrusions, and lineally coextensive therewith;
fabricating a separate, lineally-extending lens of a plastics composition and having opposed parallel, lineally-extended free edge portioins traversing a lineal expanse of said lens;
forming each opposed said lineally extended free edge portion of said lens with a configuration for matingly connecting said lens to said upwardly extending said wall sections of said extrusioin for sealing therewith along a full lineal expanse of said extrusion and said lens, and establishing an elongate, open-ended housing section having any sought lineal expanse;
fabricating a first casting, and forming said first casting with a plate-like configuration to serve as an end wall appendage of said housing section at each of opposite ends of said lighting fixture;
also forming said first casting to define a perimetric contour corresponding to a perimetric contour of each end edge of said housing section, including a surmounting lens of said housing section;
forming said first casting to define as well a lattice-like wall configuration including a plurality of deviders and through openings demarking passageways in said end walls of said housing section;
forming said first casting at an inwardly-presented limit thereof with coupler means for engaging end structures of functionally-united, intercoupling, longitudinally-extending ends of inter-connected said extrusion and said lens, and also
forming said first casting at a side thereof remote from an end of said extrusion and said lens with a circumscribing perimetriuc shoulder for sealingly selectively engaging either one of a coupler ring to be sleevedly attached thereto at an end cap to be secured thereon;
said method including the further optional steps of forming a plurality of lineally joined module-like housing sections; and the further steps of
fabricating a second casting for use in the method of optionally connecting two, and optionally more, separate modular sections of said lighting fixture to one another endwise as a unitary linear array;
forming said second casting as a bilateral coupler to be secured to a free end of a said first casting mounted on an end of a body section of said body section of said lighting fixture;
forming said second casting to constitute a ring-like structure including at a circumscribing top wall thereof integrally-formed, laterally extending ring-like flanges including a first flange and a second flange; said flanges each being dimensioned and configured to overlie in sealing engagement therewith a mating said top wall of said first casting; whereby said second casting operates to establish a positive endwise joinder of two said housing sections to one another in a lineal array;
said method further including the steps of forming an end cap of a unitary one-piece configuration having a base, an upstanding endwall, and a top, and defining an integrally-formed, uninterrupted, circumscribing free edge contoured to be congruently superimposable over a corresponding said circunscribing perimetric shoulder of said first casting in sealing engagement therewith;
assembling a lighting fixture having a single housing section and including the steps of:
securedly mounting said first casting at each respective ends of said housing section in sealing engagement therewith;
affixing said end cap positively to each of opposed ends of said housing section in sealing engagement with outwardly perimetric said shoulders of said first casting; and
assembling a lighting fixture which includes two housing sections, including the steps of:
securedly mounting a first said casting at each respective ends of a first end of second said housing section;
affixing a described said first casting to each opposed ends of said first housing section and to said second housing section;
connecting a first side of said second casting to a free end of a first said housing section in sealing engagement therewith;
connecting a second said housing section to a second side of said second casting to couple two said housing sections together as a linked, lineally-extending assembly; and
affixing a said end cap to each free end of each said housing section to provide a completed, elongate, unitary, multi-sectional lighting fixture.

18. A lighting fixture as set forth in claim 1 constituting a non-lineal structure selected from the group consisting of:

two modular sections joined to one another to form an L-node, corner configured lighting fixture assembly;
four modular sections joined to one another by adapters as a fixture in the form of a closed rectangular loop;
three modular sections joined to one another by a joinder adapter to define a T node, T-shaped lighting fixture assembly; and
four modular sections joined to one another by a joinder adapter to constitute an X node, X mode configured lighting fixture.
Patent History
Publication number: 20030223231
Type: Application
Filed: May 28, 2002
Publication Date: Dec 4, 2003
Inventors: Charles A. McCarthy (Gurnee, IL), James P. Kelly (East Troy, WI)
Application Number: 10156423