阅读说明：本技术 可调整的吊架杆组合件 (Adjustable hanger rod assembly ) 是由 托尼·沈 于 2018-11-28 设计创作，主要内容包括：一种吊架杆组合件包括第一吊架杆、第二吊架杆和吊架杆固持器。所述第一吊架杆和所述第二吊架杆机械地耦合,其中所述第一吊架杆以伸缩方式相对于所述第二吊架杆滑动。所述第一吊架杆和所述第二吊架杆均包含互锁结构,所述互锁结构互锁所述第一吊架杆与所述第二吊架杆,从而减少例如反冲或坡降等横向移动。所述吊架杆固持器用以固持所述第一吊架杆或所述第二吊架杆中的至少一个。所述吊架杆固持器包含用以导引至少所述第一吊架杆的第一区段和用以导引至少所述第二吊架杆的第二区段。所述第一区段和所述第二区段还分别约束所述第一吊架杆和所述第二吊架杆的横向移动。(A hanger bar assembly includes a first hanger bar, a second hanger bar, and a hanger bar holder. The first hanger bar and the second hanger bar are mechanically coupled, wherein the first hanger bar slides in a telescoping manner relative to the second hanger bar. The first hanger bar and the second hanger bar each include an interlocking structure that interlocks the first hanger bar and the second hanger bar to reduce lateral movement such as kickback or downhill. The hanger bar holder is to hold at least one of the first hanger bar or the second hanger bar. The hanger bar holder includes a first section to guide at least the first hanger bar and a second section to guide at least the second hanger bar. The first and second sections also constrain lateral movement of the first and second hanger bars, respectively.)

1. A hanger bar assembly (200), comprising:

a first hanger bar (66A) having a first interlocking structure (75A);

a second hanger bar (66B) having a second interlocking structure (75B) to interlock with the first hanger bar, the second hanger bar mechanically coupled to the first hanger bar such that the second hanger bar slides relative to the first hanger bar in a telescoping manner along a first axis; and

a hanger bar holder (56) to hold at least one of the first hanger bar or the second hanger bar,

wherein:

the first interlock structure constrains lateral movement of the second hanger bar relative to the first hanger bar along a second axis perpendicular to the first axis and a third axis perpendicular to the first axis and the second axis;

the second interlocking structure constrains lateral movement of the first hanger bar to the second hanger bar along the second and third axes;

the hanger bar holder includes a frame (58) comprising:

a first section (80A) to guide at least the first hanger bar through the hanger bar holder along the first axis and constrain lateral movement of the first hanger bar relative to the hanger bar holder along the second and third axes; and

a second section (80B) to guide at least the second hanger bar through the hanger bar holder along the first axis and constrain lateral movement of the second hanger bar relative to the hanger bar holder along the second and third axes,

wherein the frame partially surrounds the first hanger bar and the second hanger bar to form a passageway (82) for the first hanger bar and the second hanger bar.

2. The hanger bar assembly of claim 1, wherein the frame includes an opening (84) that interfaces the passageway and spans a length of the hanger bar holder parallel to the first axis.

3. The hanger bar assembly of claim 1, wherein the frame of the hanger bar holder includes a first portion (88B) having a first length equal to a length of the hanger bar holder along the first axis and a second portion (88A) having a second length along the first axis different from the first length, the first and second portions contacting at least one of the first hanger bar or the second hanger bar.

4. The hanger bar assembly of claim 1, wherein the first hanger bar and the second hanger bar are substantially identical or identically shaped such that the first assembly of the first hanger bar and the second hanger bar have a cross-sectional shape of at least one of a plane of symmetry or a plane of anti-symmetry.

5. The hanger bar assembly of claim 4, wherein the first hanger bar has a cross-sectional shape based on a curve having a first endpoint and a second endpoint such that a first tangent vector corresponding to the first endpoint is perpendicular to a second tangent vector corresponding to the second endpoint.

6. The hanger bar assembly of claim 1, wherein the frame of the hanger bar holder has a substantially uniform thickness.

7. The hanger bar assembly of claim 6, wherein the first hanger bar and the second hanger bar each have a thickness substantially equal to the substantially uniform thickness of the frame of the hanger bar holder.

8. The hanger bar assembly of claim 1, wherein the hanger bar holder is a single continuous structure.

9. The hanger bar assembly of claim 8, wherein the hanger bar holder is not significantly foldable or bendable.

10. The hanger bar assembly of claim 1, wherein the hanger bar holder does not include a hinge.

11. The hanger bar assembly of claim 1, wherein the hanger bar holder does not include a hasp and/or a hasp catch.

12. The hanger bar assembly of claim 1, wherein the first section of the frame forms a first track that only guides the first hanger bar and the second section of the frame forms a second track that only guides the second hanger bar.

13. The hanger bar assembly of claim 1, wherein the hanger bar holder includes a third section having at least one coupling mechanism to mechanically couple the hanger bar holder to a housing, wherein the housing is at least one of a junction box, a tank housing, a bracket, or a light fixture frame.

14. The hanger bar assembly of claim 13, wherein the at least one coupling mechanism is at least one of a screw fastener or a rivet.

15. The hanger bar assembly of claim 13, wherein the third section forms a gap between the hanger bar holder and at least one of the first hanger bar or the second hanger bar, the gap providing a space to accommodate at least a portion of the at least one coupling mechanism.

16. The hanger bar assembly of claim 13, wherein each of the at least one coupling mechanisms includes a stud to be inserted into a slot on the housing, the slot oriented to enable adjustment of the hanger bar assembly along at least one of the second axis or the third axis.

17. The hanger bar assembly of claim 1, wherein the first hanger bar is shaped to generate a frictional force between the first hanger bar and the second hanger bar,

the frictional force is sufficiently large to maintain the relative position when no external force for adjusting the relative position of the first hanger bar to the second hanger bar is applied to the hanger bar assembly.

18. A hanger bar assembly (200), comprising:

a first hanger bar (66A) having a first interlocking structure (75A);

a second hanger bar (66B) having a second interlocking structure (75B) to interlock with the first hanger bar, the second hanger bar mechanically coupled to the first hanger bar such that the second hanger bar slides relative to the first hanger bar in a telescoping manner along a first axis; and

a hanger bar holder (56) to hold at least one of the first hanger bar or the second hanger bar,

wherein:

the first interlock structure constrains lateral movement of the second hanger bar relative to the first hanger bar along a second axis perpendicular to the first axis and a third axis perpendicular to the first axis and the second axis;

the second interlocking structure constrains lateral movement of the first hanger bar to the second hanger bar along the second and third axes;

the hanger bar holder (56) includes a frame (58),

wherein the frame at least partially surrounds the first hanger bar and the second hanger bar so as to form a passage (82), the frame having an opening (84) that interfaces the passage and spans a length of the hanger bar holder that is parallel to the first axis; and is

The frame includes a first portion (88B) having a first length equal to a length of the hanger bar holder along the first axis and a second portion (88A) having a second length along the first axis different from the first length, the first and second portions contacting at least one of the first hanger bar or the second hanger bar.

19. The hanger bar assembly of claim 18, the frame further comprising:

a first section to guide at least the first hanger bar through the hanger bar holder along the first axis and constrain lateral movement of the first hanger bar relative to the hanger bar holder along the second and third axes; and

a second section to guide at least the second hanger bar through the hanger bar holder along the first axis and constrain lateral movement of the second hanger bar relative to the hanger bar holder along the second and third axes.

20. The hanger bar assembly of claim 19, wherein the hanger bar holder includes a third section having at least one coupling mechanism to mechanically couple the hanger bar holder to a housing, wherein the housing is at least one of a junction box, a can housing, a bracket, or a light fixture frame.

21. The hanger bar assembly of claim 20, wherein the at least one coupling mechanism is at least one of a screw fastener or a rivet.

22. The hanger bar assembly of claim 20, wherein the third section forms a gap between the hanger bar holder and at least one of the first hanger bar or the second hanger bar, the gap providing a space to accommodate at least a portion of the at least one coupling mechanism.

23. The hanger bar assembly of claim 20, wherein each of the at least one coupling mechanisms includes a stud to be inserted into a slot on the housing, the slot oriented to enable adjustment of the hanger bar assembly along at least one of the second axis or the third axis.

24. A hanger bar assembly (200), comprising:

a first hanger bar (66A);

a second hanger bar (66B) mechanically coupled to the first hanger bar such that the second hanger bar slides relative to the first hanger bar in a telescoping manner along a first axis; and

a hanger bar holder (56) to hold at least one of the first hanger bar or the second hanger bar, the hanger bar holder including a frame (58) comprising:

a first section (80A) to guide at least the first hanger bar through the hanger bar holder along the first axis and constrain lateral movement of the first hanger bar relative to the hanger bar holder along a second axis perpendicular to the first axis and a third axis perpendicular to the first and second axes; and

a second section (80B) to guide at least the second hanger bar through the hanger bar holder and constrain lateral movement of the second hanger bar relative to the hanger bar holder along the second and third axes,

wherein:

the hanger bar holder is formed as a single continuous part;

said hanger bar holder is not significantly foldable or bendable;

the hanger bar holder does not include a hinge; and is

The hanger bar holder does not include a hasp and/or a hasp catch.

25. The hanger bar assembly of claim 24, wherein the first hanger bar has a first interlocking feature that constrains lateral movement of the second hanger bar relative to the first hanger bar along the second and third axes,

wherein the second hanger bar has a second interlocking feature that constrains lateral movement of the first hanger bar to the second hanger bar along the second and third axes.

26. The hanger bar assembly of claim 25, wherein the first hanger bar and the second hanger bar are substantially identical or identically shaped.

27. The hanger bar assembly of claim 26, wherein the first hanger bar is shaped to generate a frictional force between the first hanger bar and the second hanger bar,

the frictional force is sufficiently large to maintain the relative position when no external force for adjusting the relative position of the first hanger bar to the second hanger bar is applied to the hanger bar assembly.

28. The hanger bar assembly of claim 26, wherein the first hanger bar includes a mechanical stop to prevent separation of the first hanger bar from the second hanger bar.

29. The hanger bar assembly of claim 25, wherein the hanger bar holder includes a third section having at least one coupling mechanism to mechanically couple the hanger bar holder to a housing, wherein the housing is at least one of a junction box, a can housing, a bracket, or a light fixture frame.

30. The hanger bar assembly of claim 29, wherein the at least one coupling mechanism is at least one of a screw fastener or a rivet.

31. The hanger bar assembly of claim 29, wherein the third section forms a gap between the hanger bar holder and at least one of the first hanger bar or the second hanger bar, the gap providing a space to accommodate at least a portion of the at least one coupling mechanism.

32. The hanger bar assembly of claim 29, wherein each of the at least one coupling mechanisms includes a stud to be inserted into a slot on the housing, the slot oriented to enable adjustment of the hanger bar assembly along at least one of the second axis or the third axis.

Background

Recessed lighting systems are typically mounted into an opening in a ceiling or wall. Modern recessed lighting systems generally consist of a bezel, a light source module, driver circuitry, a junction box and a set of hanger bars. The driver is insulated from other parts and components of the recessed lighting system containing the light source module by using the insulation provided by the junction box when the light source module is received therein. The driver is electrically coupled to the light source module using wires or other conduits so that the driver can power the light source module to emit light.

The junction box, the tank, and other components of the recessed lighting system are attached to a hanger bar so that the hanger bar can support the components of the recessed lighting system in a wall or ceiling of a structure. For example, the junction box may be attached to the hanger bar by using screws and bolts that anchor the junction box and the driver.

The commonly owned U.S. patent publication 2015/0233506 invention significantly advances the state of the art or recessed lighting systems having such components. However, there is still an opportunity for further improvement.

Disclosure of Invention

The present inventors have recognized and appreciated that a hanger bar assembly directly coupled to a lighting system housing, such as a junction box, a tank housing, a bracket, or a light fixture frame, provides several benefits to the installation of a lighting system, such as allowing the housing to be positioned in a preferred location between adjacent support structures, such as joists or cross beams. The direct coupling of the hanger bar assembly to the lighting system housing substantially reduces the increased volume and size of conventional recessed lighting systems, which can reduce raw material costs and shipping costs.

However, the present inventors have also recognized and appreciated several shortcomings of conventional hanger bar assemblies. For example, gaps between coupled hanger bars may cause kickback and fall, particularly when the hanger bars extend to cover large distances between adjacent support structures. In addition, hanger bars are generally different sizes; thus, conventional hanger bar holders are designed to accommodate larger hanger bars. If the housing is mounted close to the support structure, the hanger bar may need to be extended so that only one hanger bar is held by the hanger bar holder. If the smaller hanger bar is held in the hanger bar holder, a large gap may be formed between the smaller hanger bar and the hanger bar holder, resulting in instability in the hanger bar assembly.

The present disclosure is therefore directed to various inventive hanger bar assemblies that (1) interlock the hanger bars to reduce unwanted lateral kickback and descent, and (2) constrain each of the hanger bars to the hanger bar holders to reduce unwanted lateral movement between the hanger bars and the hanger bar holders.

In one example, a hanger bar assembly includes: a first hanger bar having a first interlocking structure; a second hanger bar having a second interlocking structure for interlocking with the first hanger bar; and a hanger bar holder for holding at least one of the first hanger bar or the second hanger bar. A second hanger bar is mechanically coupled to the first hanger bar such that the second hanger bar slides relative to the first hanger bar in a telescoping manner along a first axis. The first interlock structure constrains lateral movement of the second hanger bar relative to the first hanger bar along a second axis perpendicular to the first axis and a third axis perpendicular to the first axis and the second axis. The hanger bar holder also includes a frame including a first section to guide at least the first hanger bar through the hanger bar holder along a first axis and constrain lateral movement of the first hanger bar relative to the hanger bar holder along a second axis and a third axis. The frame also includes a second section to guide at least the second hanger bar through the hanger bar holder along the first axis and constrain lateral movement of the second hanger bar relative to the hanger bar holder along the second and third axes. The frame also forms a passage that partially surrounds the first hanger bar and the second hanger bar.

It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are considered part of the inventive subject matter disclosed herein. It is also to be understood that the terms explicitly used herein, which may also appear in any disclosure incorporated by reference, are to be given the meanings most consistent with the specific concepts disclosed herein.

Drawings

Those skilled in the art will appreciate that the drawings are primarily for illustrative purposes and are not intended to limit the scope of the inventive subject matter described herein. The figures are not necessarily to scale; in some instances, various aspects of the inventive subject matter disclosed herein may be shown exaggerated or enlarged in the drawings to help to understand different features. In the drawings, like reference numbers generally refer to like features (e.g., functionally similar and/or structurally similar elements).

Fig. 1 shows an exploded view of a recessed lighting system according to an embodiment.

Fig. 2 shows how the junction box and the spreader holder may be moved and positioned horizontally along the spreader bar and vertically along the axis Y according to one embodiment.

Fig. 3 is a front view of an exemplary hanger bar assembly having a pair of hanger bars and a hanger bar holder according to some inventive embodiments of the present disclosure.

Fig. 4A is a front view of another exemplary hanger bar assembly having a pair of hanger bars and a hanger bar holder according to some inventive embodiments of the present disclosure.

Fig. 4B is a front view of the hanger bar of fig. 4A detailing the curves used to define the cross-sectional shape of the hanger bar.

Fig. 4C is a front view of the hanger bar of fig. 4A detailing the anti-symmetric planes when the hanger bars are assembled together.

Fig. 5A shows a perspective view of the hanger bar assembly of fig. 4A with a first hanger bar and a second hanger bar disposed within the hanger bar holder.

Fig. 5B shows a perspective view of the hanger bar assembly of fig. 4A with the first hanger bar positioned such that the first hanger bar is no longer disposed within the hanger bar holder.

Fig. 5C illustrates an enlarged view of the hanger bar holder of fig. 5A.

Detailed Description

Embodiments of the present invention will now be described in detail with reference to the drawings, which are provided as illustrative examples of embodiments so as to enable those skilled in the art to practice their clear embodiments and alternatives. It is worthy to note that the figures and examples below are not intended to limit the scope of embodiments of the present disclosure to a single embodiment, but rather other embodiments are possible by virtue of interchange of some or all of the described or illustrated elements. Furthermore, where certain elements of embodiments of the present invention may be partially or fully implemented using known components, those of such known components that are only necessary for an understanding of the embodiments of the present invention will be described, and detailed descriptions of other portions of such known components will be omitted so as not to obscure the embodiments of the present invention. In this specification, unless explicitly stated otherwise herein, embodiments showing individual components should not be considered limiting; rather, the present disclosure is intended to cover other embodiments that include a plurality of the same components and vice versa. Moreover, it is not the intention of the applicants that any term in the specification or the appended claims be ascribed an uncommon or special meaning unless explicitly set forth as such. Furthermore, embodiments of the present invention encompass current and future known equivalents to the known components referred to herein by way of illustration.

Fig. 1 shows an exploded view of an example recessed lighting system 1. The recessed lighting system 1 may comprise a junction box 2, a unitary casting 3, a rim 4, a set of hanger bars 5 and a set of hanger holders 6. In some embodiments, the unified casting 3 may contain the light source modules and drivers in a single compact unit. As will be described in further detail below, the recessed lighting system 1 provides a relatively compact and economical design that allows the light source module 3 to be moved and adjusted while complying with various building and safety codes/regulations. Each of the elements of the recessed lighting system 1 will be explained below by way of example.

The junction box 2 is a structure that separates (e.g., insulates) the internal components of the recessed lighting system 1 containing the electric wires/cables from the items inside the ceiling or low space in which the junction box 2 has been installed. In one embodiment, the junction box 2 may be a single or double junction box with a fire rating of up to two hours, as described in the National Electrical Code (NEC) and the Underwriters Laboratories (UL). The junction box 2 may receive the wires 9A from an electrical system (e.g., 120VAC or 277VAC) within the building or structure in which the recessed lighting system 1 is installed. Wires 9A from the structure may be connected to corresponding wires 9B of the unified casting 3.

Although fig. 1 shows a standard "2 x2" junction box, the junction box 2 may be implemented with an external housing, such as described in co-pending U.S. patent publication No. 2016/0312987, the contents of which are incorporated herein by reference in their entirety.

The casting 3 is a shell and/or enclosure that further prevents heat from the light source module and driver from being exposed to items (e.g., insulation) inside the ceiling or low space in which the recessed lighting system 1 has been installed. Example light source modules and drivers that may be housed in the casting 3 used in the system 1 are described in more detail in co-pending U.S. patent publication No. 2015/0009676, the contents of which are incorporated herein by reference in their entirety.

In one embodiment, wires 9A received by the junction box 2 from the electrical system of the building or structure may be coupled to wires 9B of the casting 3. As shown, the wires 9A and 9B are connected together using interlocking connectors (along with the casting 3) that may be contained within the cassette 2. However, in other embodiments, the wires 9A may be coupled to the wires 9B through the use of an electrical cover or other means, and may remain outside the cassette 2 (while the casting 3 remains inside). The wires 9B of the casting 3 may terminate in a connection with a driver 8 mounted within the casting 3. When the wires 9A and 9B are connected, power may be transferred from the power system of the building or structure to the driver to enable the driver to power the light source module.

In one embodiment, the recessed lighting system 1 may comprise a bezel 4. The main purpose of the edge strip 4 is to cover the exposed edge of the ceiling or wall where the hole of the resident recessed lighting system 1 is formed, while still allowing light from the light source module 3 to be emitted into the room through the aperture 15. In doing so, the edge strip 4 helps the recessed lighting system 1 to appear seamlessly integrated into a ceiling or wall. In one embodiment, the edge strip 4 will be attached to the casting 3, while in other embodiments the edge strip 4 will be attached to the junction box 2. The edge strips 4 may be coupled to the casting 3 and/or the junction box 2 using any connection mechanism including resin, clips, screws, bolts, or clamps. In one embodiment, the edge strips 4 may contain grooves and/or slots to couple to corresponding grooves and/or slots of the casting 3 and/or the junction box 2 using a twist-lock friction connection without the use of a separate tool or other device.

In one embodiment, the recessed lighting system 1 may comprise a set of hanger bars 5 as shown in fig. 1. The hanger bar 5 may be a rigid elongate member that is connected between adjacent joists and/or cross beams in a wall or ceiling of the structure (see fig. 2). In one embodiment, each of the hanger bars 5 may be telescopic such that each hanger bar 5 may be extended or retracted to meet the gap between the joists and/or the cross beam. In this embodiment, each hanger bar 5 may include an inner bar element 16A and an outer bar element 16B. The inner rod element 16A may be inserted and then retained within a railing structure 17 formed on the outer rod element 16B. In this configuration, the inner bar element 16A can slide relative to the outer bar element 16B to change the overall length of each hanger bar 5. In one embodiment, the railing structure 17 in the outer bar element 16B may be formed by a set of guides. The guides may be bent tabs of the outer bar element 16B or tabs coupled to the outer bar element 16B. In this way, the railing structure 17 forms a channel for the inner rod element 16A.

In one embodiment, each of the hanger bars 5 may contain a set of mounting blocks 19. The mounting blocks 19 may be used to couple the hanger bar 5 to joists and/or beams in a wall or ceiling of a structure. For example, as shown in fig. 1, the mounting block 19 may include holes for receiving screws and/or nails or other fasteners that enable the hanger bar 5 to be securely attached to the building structure. Although shown in fig. 1 and described above with respect to holes and screws, in other embodiments, other attachment mechanisms may be used in conjunction with mounting block 19, including resins, clips, or clamps, to attach rod 5 to the building structure. In one embodiment, the mounting block 19 may be integrated in an indivisible structure along with the inner and outer rod elements 16A, 16B, while in other embodiments, as shown in fig. 1, the mounting block 19 may be coupled to the inner and outer rod elements 16A, 16B using one or more attachment mechanisms (e.g., screws, bolts, resin, clips, or clamps). Using the telescoping and mounting features described above, the recessed lighting system 1 can be mounted in almost all 2"X2" to 2"X16" wood joist configurations, metal stud configurations, and t-bar ceiling configurations.

In one embodiment, the recessed lighting system 1 may include a set of hanger holders 6. The hanger holders 6 may be configured to slide or otherwise move along the corresponding hanger bar 5. In one embodiment, the hanger holder 6 may include an attachment mechanism 21 for coupling with the junction box 2. The attachment mechanism 21 may be any mechanism that allows the junction box 2 to be removably connected to the hanger bar 5. For example, as shown in fig. 1, the attachment mechanism 21 may be a hole for receiving a screw or bolt therein. However, in other embodiments, the attachment mechanism 21 may include a resin, clip, and/or clamp that allows the hanger holder 6 to be coupled to the junction box 2. By being coupled to the hanger holder 6, the junction box 2 together with the light source module and the driver therein can be moved to a desired position across the hanger bar 5, as shown in fig. 2. Thus, during installation of the recessed lighting system 1, by attaching the mounting blocks 19 to the cross beams, the hanger bar 5 may be installed within the gap between the cross beams within the structure, and then the junction box 2, with the light source modules 7 and drivers 8 therein, may be moved by the installer to a desired position along the hanger bar 5 and within the gap.

According to certain aspects, the hanger holder 6 described above allows the terminal box 2 to move in a direction parallel to the longitudinal axis of the hanger bar 5. Thus, the junction box 2 can be moved to a preferred position between a set of joists or beams in the structure and then locked into place using the mechanism 21. By being configured such that the junction box 2, with the light source modules and drivers therein, is coupled to a unified set of movable elements that help position the combined structure, the recessed lighting system 1 eliminates the increased volume and size of conventional recessed lighting systems. This compact design provides a affordable design by cutting down the cost of raw materials and other components, and reduces shipping costs by reducing volume.

While the hanger bar 5 and hanger holder 6 described above in connection with the lighting system 1 provide many advantages over conventional recessed lighting systems, the applicant has realised that there are still certain opportunities for improvement.

For example, fig. 3 is a front view of an exemplary hanger bar assembly 100 of a hanger bar 5 and a hanger holder 6, such as those shown in fig. 1 and 2. As described above and as shown in fig. 3, hanger bar 5 and hanger holder 6 are fabricated in such a way that one of the rods 16B slides telescopically over the other rod 16A to adjust various joist spacings. The holder 6 is typically made to cover the larger of the two (16B) to allow lateral movement of the junction box (not shown). When the joist spacing is large (e.g., greater than 16 inches), any gap between the slides 16A, 16B can create vertical backlash and droop in the junction box. Also, if the junction box has to be mounted close to the joist, and the holder 6 is thus only located on one of the sheets (e.g. 16A) due to the telescopic extension between the sheets 16A and 16B, there will be a large gap between the hanger bar 5 and the holder 6 at the sheet 16A, which will lead to instability.

Fig. 4A is a front view of a hanger bar assembly 200 according to some inventive embodiments of the present disclosure. As shown, the hanger bar assembly 200 may include a first hanger bar 66A, a second hanger bar 66B and a hanger bar holder 56. The first hanger bar 66A can be mechanically coupled to the second hanger bar 66B such that the first hanger bar 66A slides relative to the second hanger bar 66B in a telescoping manner along the first axis. The hanger bar holder 56 may be for holding at least one of the first hanger bar 66A or the second hanger bar 66B such that the first hanger bar 66A and/or the second hanger bar 66B slides telescopically relative to the bar hanger holder 56 along the first axis. The hanger bar holder 56 may also be used to couple the hanger bar assembly 200 to various housings of a lighting system (not shown) for assembly and installation, including but not limited to a junction box, a tank housing, a light fixture frame, or a bracket.

The first hanger bar 66A and the second hanger bar 66B can each be a rail-like structure that are coupled together such that the first hanger bar 66A and the second hanger bar 66B can slide relative to each other along a first axis. The first hanger bar 66A and the second hanger bar 66B can thus be extended or retracted to accommodate various spacings between support structures (e.g., joists), which are used for attachment during installation of a lighting system coupled to the hanger bar assembly 200. As shown in fig. 4A, the first hanger bar 66A may have a cross-sectional shape of substantially uniform thickness. The uniform thickness may ease manufacturing by allowing the first hanger bar 66A to be formed from a thin sheet of material. For example, the first hanger bar 66A may be manufactured by bending a metal sheet such that a desired rail-like structure is formed. In some embodiments, the first hanger bar 66A and the second hanger bar 66B may each have a thickness that is substantially equal to each other.

As shown in fig. 4B, the cross-sectional shape of the first hanger bar 66A may be based in part on a curve 74A having a first end point 76A and a second end point 77A. A first tangent line corresponding to the first end point 76A quantifies the orientation of the surface of the first hanger bar 66A at the first end point 76A. Similarly, a second tangent vector corresponding to second end point 77A defines the orientation of the surface of first hanger bar 66A at second end point 77A. The relative angle between the first tangent vector and the second vector may vary between about 0 degrees (e.g., the first tangent vector and the second tangent vector are parallel) to about 90 degrees (e.g., the first tangent vector and the second tangent vector are perpendicular).

The cross-sectional shape of the first hanger bar 66A may include an interior passage 68A designed to receive an interlocking structure 75B of the second hanger bar 66B, which will be discussed in more detail below. The second hanger bar 66B can similarly include an internal passage 68B to receive the interlocking structure 75A of the first hanger bar 66A. Mechanical stops 70A and 72A may also be disposed at opposite ends of the first hanger bar 66A along the first axis. The second hanger bar 66B can similarly include mechanical stops 70B and 72B disposed at opposite ends of the second hanger bar 66B along the first axis. The mechanical stops 70A, 72A, 70B, and 72B may provide a mechanical barrier to prevent the first hanger bar 66A and the second hanger bar 66B from separating, particularly when the first hanger bar 66A is fully extended from the second hanger bar 66B. For example, mechanical stop 70A may physically contact mechanical stop 72B. Similarly, mechanical stop 70B may physically contact 72A.

The first hanger bar 66A may include an interlocking structure 75A for interlocking the first hanger bar 66A with the second hanger 66B. The interlocking structure 75A reduces unwanted lateral movement (e.g., lateral kickback or descent) between the first hanger bar 66A and the second hanger bar 66B, which can improve the structural stability of the hanger bar assembly 200, particularly when the first hanger bar 66A is fully extended from the second hanger bar 66B such that a small portion of the first hanger bar 66A overlaps the second hanger bar 66B. As an exemplary reference coordinate system, the first axis may correspond to a horizontal axis of motion; thus, lateral motion between hanger bars 66A and 66B can be reduced along a second axis (e.g., horizontal lateral motion) perpendicular to the first axis and a third axis (e.g., vertical lateral motion) perpendicular to both the first and second axes. The reduction of unwanted lateral motion can be achieved in part by an interlock structure 75A having structural features that physically contact multiple locations along the second hanger bar 66B such that movement along the second and third axes between the first and second hanger bars 66A, 66B is limited. The interlocking structure 75A can be integrated into the hanger bar 66A such that the first hanger bar 66A is a single continuous structure. The second hanger bar 66B can similarly include an interlocking structure 75B, which can also be used to interlock the second hanger bar 66B with the first hanger bar 66A.

For example, fig. 4A shows that the interlock structure 75A can have a C-shaped cross-section that is primarily disposed within the interior passage 68B of the second hanger bar 66B. The interlock structure 75A contains several areas that physically contact the inner wall of the second hanger bar 66B within the interior passage 68B, thereby limiting unwanted lateral movement along the second and third axes. The second hanger bar 66B can similarly include an interlocking structure 75B, which can also have a C-shaped cross-section disposed primarily within the interior passage 68A of the first hanger bar 66A. It should be appreciated that at least one of the interlocking structures 75A or 75B can be used to interlock the first hanger bar 66A and the second hanger bar 66B. However, the use of two interlocking structures 75A and 75B may also improve the structural stability of the hanger bar assembly 200 by increasing the number of areas where the first hanger bar 66A physically contacts the second hanger bar 66B.

First hanger bar 66A physically contacts second hanger bar 66B through respective interlocking structures 75A and 75B and/or other areas of first hanger bar 66A that can dock with second hanger bar 66B, respectively, without having to provide mechanical restraint to lateral motion. In some embodiments, the first hanger bar 66A and/or the second hanger bar 66B may be shaped and sized to generate a frictional force between the first hanger bar 66A and the second hanger bar 66B along the respective regions where physical contact occurs. The frictional force may be partially used to maintain the relative position between the first hanger bar 66A and the second hanger bar 66B. For example, a user may apply a force to adjust the relative position of the first hanger bar 66A to the second hanger bar 66B during installation. The friction force can be tailored to be sufficiently large so that the relative position between the first hanger bar 66A and the second hanger bar 66B is maintained once the user no longer applies a force to the hanger bar assembly 200.

In some embodiments, the first hanger bar 66A and the second hanger bar 66B can be substantially the same or the same in shape and/or size. For such cases, the assembly of the first hanger bar 66A and the second hanger bar 66B results in a cross-sectional geometry that may contain at least one plane of symmetry and/or one plane of anti-symmetry. For example, fig. 4C shows that the first hanger bar 66A and the second hanger bar 66B when assembled may include at least two anti-symmetric planes, e.g., plane 202A and plane 202B.

Various metals and plastics may be used to form the first hanger bar 66A and the second hanger bar 66B, including but not limited to aluminum, carbon steel, stainless steel, polyethylene, or any other material known to those skilled in the art. Depending on the materials used to form the first hanger bar 66A and the second hanger bar 66B, the first hanger bar 66A and the second hanger bar 66B may be manufactured using various manufacturing techniques, including, but not limited to, bending a sheet to form a desired cross-sectional shape, or extruding the material through a die, wherein the die defines the desired cross-sectional shape.

The hanger bar assembly 200 may also include a hanger bar holder 56 for holding at least one of the first hanger bar 66A or the second hanger bar 66B. The hanger bar holder 56 may be used to guide the first hanger bar 66A and/or the second hanger bar 66B in a telescoping manner while providing mechanical attachment to a housing (e.g., junction box, tank housing) of the lighting system as described above. The hanger bar holder 56 may include a frame 58 that forms a passage 82 that partially surrounds the first hanger bar 66A and/or the second hanger bar 66B. In some embodiments, the frame 58 may include an opening 84 that interfaces with the passageway 82. The opening 84 may span the length of the hanger bar holder 56 parallel to the first axis. The inclusion of the opening 84 improves manufacturability because a completely closed via 82 is more difficult to manufacture. Additionally, the inclusion of intermediate structural features (e.g., walls 86 in hanger bar holder 56 as shown in fig. 4D) would require an additional more complex manufacturing process, which increases the time and cost of manufacturing the hanger bar holder 56.

The frame 58 may have a cross-sectional shape of substantially uniform thickness. Like the first hanger bar 66A and the second hanger bar 66B, having a cross section of uniform thickness may ease manufacturing by allowing the hanger bar holder 56 to be formed from a sheet. In some embodiments, the thickness of the frame 58 may be substantially equal to the respective thicknesses of the first hanger bar 66A and the second hanger bar 66B, thus allowing the hanger bar holder 56, the first hanger bar 66A and the second hanger bar 66B to all be fabricated from the same sheet of material.

In some implementations, the hanger bar holders 56 may be subdivided into sections according to their function in the bar hanger assembly 200. For example, fig. 4D shows that the hanger bar holder 56 may be subdivided into a first section 80A, a second section 80B, and a third section 80C. The first section 80A may be used to guide at least the first hanger bar 66A along a first axis by the hanger bar holder 56. The first section 80A may also serve to constrain lateral movement of the first hanger bar 66A relative to the hanger bar holder 56 along the second and third axes as defined above. The second section 80B may be similar to the first section 80A in that the second section 80B may be used to guide the second hanger bar 66B along the first axis through the hanger bar holder 56 and constrain lateral movement of the second hanger bar 66B. The third section 80C may be used to facilitate coupling of the hanger bar holder 56 to a housing of a lighting system, as will be discussed below.

In some embodiments, the first section 80A of the frame 58 forms a first track that only guides the first hanger bar 66A, and the second section 80B of the frame 58 forms a second track that only guides the second hanger bar 66B. For example, fig. 4C shows only the first section 80A physically contacting the first hanger bar 66A. Similarly, only the second section 80B physically contacts the second hanger bar 66B. As shown, the intermediate wall 86 may overlap between the first section 80A and the second section 80B; however, a first side of intermediate wall 86 contacts only first hanger bar 66A and a second side of intermediate wall 86 contacts only second hanger bar 66B.

In some implementations, the hanger bar holder 56 can constrain lateral motion of the first hanger bar 66A and the second hanger 66B independently of each other, such that the hanger bar holder 56 can hold only one of the first hanger bar 66A or the second hanger 66B without affecting the constraint imposed to reduce lateral movement. For example, the hanger bar holder 56 may be disposed adjacent to the first support structure. To reach adjacent the second support structure, the first hanger bar 66A and the second hanger bar 66B may need to be fully extended such that only one of the first hanger bar 66A or the second hanger bar 66B is retained within the hanger bar holder 56. As described above, a large gap is typically formed between the conventional hanger bar holder and the conventional hanger bar, resulting in instability of the hanger bar assembly. By independently constraining the lateral motion of the first hanger bar 66A and the second hanger bar 66B, the hanger bar holder 56 can substantially reduce such instability.

The hanger bar holder 56 may have a length parallel to the first axis that covers a portion of the first hanger bar 66A and/or the second hanger bar 66B. In addition, the hanger bar holder 56 may include different portions each having a different length. For example, fig. 5C shows a perspective view of the hanger bar holder 56. As shown, the portion 88A corresponding to the first section 80A may have a shorter length than the portion 88B corresponding to the second section 80B across the length of the hanger bar holder 56. The inclusion of variable length portions in the hanger bar holder 56 may allow for multiple support structures to be formed along the length of the hanger bar holder 56. For example, portion 88A may be used to form contact and guide first section 80A of first hanger bar 66A, while portion 88B allows intermediate wall 86 to be formed to contact and guide both first hanger bar 66A and second hanger bar 66B. In addition, the use of the variable length portion may also reduce the amount of material used to manufacture the hanger bar holders 56.

The hanger bar holder 56 may be a single continuous structure, which further eases manufacturing. It should be appreciated that the hanger bar holder 56 in the present disclosure does not require additional structural features for assembly and/or adjustment of the hanger bar assembly 200 as is present in conventional hanger bar holder structures. For example, the hanger bar holder 56 need not be significantly foldable and/or bendable. In another example, the hanger bar holder 56 need not include a hinge. In yet another example, the hanger bar holder 56 need not include snaps and/or snap locks to enclose the first hanger bar 66A and/or the second hanger bar 66B.

As described above, the third section 80C may be used to facilitate coupling of the hanger bar holder 56 to the housing of the lighting system. In some implementations, the hanger bar holders 56 may be integrated into the housing of the lighting system (e.g., the hanger bar holders are integrated onto the sheet metal frame of the light fixture housing). The third section 80C may include at least one coupling mechanism to mechanically couple the hanger bar holder 56 to a housing, which again may include, but is not limited to, a junction box, a tank housing, a bracket, or a light fixture frame. Various types of coupling mechanisms may be used, including but not limited to screw fasteners or rivets. For example, fig. 5C shows the hanger bar holder 56 having two coupling mechanisms 90, in this case screw holes for receiving corresponding screw fasteners.

The coupling mechanism may also include a stud (i.e., a protruding rod). The stud may be inserted into a slot on a housing of the lighting system such that the stud is adjustable along the slot. The slot may be oriented along at least one of the second axis or the third axis. For example, if the first axis is a horizontal axis, a slot oriented along a third axis would allow the hanger bar assembly 200 to be adjustable along a vertical axis. Once inserted, the stud may be secured from the opposite side by another fastener (e.g., a dished screw) to secure the hanger bar assembly 200 to a desired position along the slot on the housing.

In some embodiments, the third section 80C may protrude away from the first and second sections 80A, 80B to form a gap 92 between the frame 58 of the hanger bar holder 56 and the second hanger bar 66B. In some embodiments, the gap 92 may actually be formed between the hanger bar holder 56 and the first hanger bar 66A. Gap 92 may provide a space for accommodating at least a portion of coupling mechanism 90. For example, the gap 90 may contain the head of a screw fastener that is coupled to the housing of the lighting system before the first hanger bar 66A and the second hanger bar 66B are inserted into the passageway 82 of the hanger bar holder 56.

Various metals and plastics may be used to form the hanger bar holder 56, including but not limited to aluminum, carbon steel, stainless steel, polyethylene, or any other material known to those skilled in the art. Depending on the material used to form the hanger bar holder 56, various manufacturing techniques may be used for manufacturing, including but not limited to bending a sheet to form the desired cross-sectional shape of the frame 58, or extruding the material through a die, where the die defines the desired cross-sectional shape of the frame 58.

Fig. 5A shows a perspective view of the hanger bar assembly 200 with the first hanger bar 66A and the second hanger 66B held by the hanger bar holder 56. As shown, the hanger bar holder 56 may independently hold a first hanger bar 66A and a second hanger bar 66B. Additionally, the first hanger bar 66A and the second hanger bar 66B can be interlocked using interlocking structures 75A and 75B (not shown). As shown, the first hanger bar 66A and the second hanger bar 66B may extend to traverse a large spacing between support structures. Structural stability is preserved due in part to the interlocking structures 75A and 75B, which prevents backlash and drooping from gaps between the first hanger bar 66A and the second hanger bar 66B.

Fig. 5B shows a perspective view of the hanger bar assembly 200 with the hanger bar holders 56 (which may be attached to the housing of the lighting system) disposed proximate to the support structure (not shown) such that only the first hanger bar 66A is held by the hanger bar holders 56 while the second hanger bar 66B extends fully to cover the spacing between adjacent support structures. As described above, the first section 80A of the hanger bar holder 56 may constrain unwanted lateral movement between the first hanger bar 66A and the hanger bar holder 56. In this way, the hanger bar holder 56 may stably support the first hanger bar 66A during installation and/or adjustment of the hanger bar assembly 200.

It will be appreciated that the first hanger bar 66A, the second hanger bar 66B and the hanger bar holder 56 may include many of the same features described above in connection with the bar 5 and the holder 6, such as the fastening mechanism 21 and the mounting block 19. However, repeated descriptions of these components are omitted herein for the sake of clarity in the embodiments of the present invention.

Conclusion

While various inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters and configurations described herein are intended to be exemplary inventive features and that other equivalents of the specific inventive embodiments described herein may be implemented. It is, therefore, to be understood that the foregoing embodiments are presented by way of example and that, within the scope of the appended claims and equivalents thereto, embodiments of the invention may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, and/or method described herein. In addition, any combination of two or more such features, systems, articles, and/or methods, if such features, systems, articles, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.

Moreover, various inventive concepts may be embodied as one or more methods, examples of which have been provided. The actions performed as part of the method may be ordered in any suitable way. Thus, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts concurrently, even though shown as sequential acts in illustrative embodiments.

All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety.

It should be understood that all definitions, as defined and used herein, override dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of defined terms.

The indefinite articles "a" and "an", as used herein in the specification and in the claims, are to be understood as meaning "at least one" unless expressly indicated to the contrary.

As used herein in the specification and claims, the phrase "and/or" should be understood to mean "either or both" of the elements so combined, i.e., the elements are present in combination in some cases and separately in other cases. Various elements listed with "and/or" should be interpreted in the same manner, i.e., "one or more" of the elements so combined. In addition to the elements specifically identified by the "and/or" clause, other elements may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, when used in conjunction with open-ended language such as "including," references to "a and/or B" may refer in one embodiment to a alone (optionally including elements other than B); in another embodiment, only B (optionally including elements other than a); in yet another embodiment, refer to both a and B (optionally including other elements), and so forth.

As used herein in the specification and claims, "or" should be understood to have the same meaning as "and/or" as defined above. For example, when separating items in a list, "or" and/or "should be interpreted as inclusive, i.e., including at least one of the plurality or list elements, but also including more than one of the plurality or list elements, and optionally additional unlisted items. Only terms explicitly indicated to the contrary, such as "only one of … …" or "exactly one of … …" or "consisting of … …" when used in the claims, will refer to the inclusion of exactly one element of a plurality or list of elements. In general, the term "or" as used herein, when preceded by an exclusive term such as "either," "one of … …," "only one of … …," or "exactly one of … …," should only be construed as indicating an exclusive alternative (i.e., "one or the other but not both"). "consisting essentially of … …" when used in the claims shall have its ordinary meaning as used in the patent law field.

As used herein in the specification and claims, the phrase "at least one," when referring to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each element specifically listed in the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows elements other than the element to which the specifically identified phrase "at least one" refers within the list of elements to optionally be present, whether or not related to those elements specifically identified. Thus, as a non-limiting example, "at least one of a and B" (or, equivalently, "at least one of a or B," or, equivalently "at least one of a and/or B") can refer in one embodiment to at least one, optionally including more than one, a, absent B (and optionally including elements other than B); in another embodiment, refers to at least one, optionally including more than one, B, with no a present (and optionally including elements other than a); in yet another embodiment, at least one, optionally including more than one a, and at least one, optionally including more than one B (and optionally including other elements), and the like.

In the claims, as well as in the specification above, all conjunctions such as "comprising," including, "" carrying, "" having, "" containing, "" involving, "" containing, "" consisting of … … and the like are to be understood as being open-ended, i.e., to mean including but not limited to. As described in the united states patent office patent examination program manual, section 2111.03, only the transition phrases "consisting of …" and "consisting essentially of …" should be closed or semi-closed transition phrases, respectively.