One-step detachable wire manager connection for indoor lighting fixtures

Abstract

A hook device is attached to the inside of the knockout plug of the lighting fixture, and removing the knockout plug pulls the wires attached to the hook device out of the lighting fixture through the plug hole, allowing easy access to external wires for connection. A conventional clamping device can then be attached to secure the external wires to the lighting fixture and close the plug hole.

Description

[Technical Field]

[0001] The present invention generally relates to providing access to internal wires contained in a metal housing, such as the internal wires of a lighting fixture. Specifically, the present invention employs a knockout plug in the housing, the interior side of which has a hook mechanism that functions as a wire manager for attaching the internal wires of the housing. Removal of the knockout plug pulls those wires out of the housing body through the knockout hole, thus allowing easy access to the wires without requiring an additional opening in the housing. [Background technology]

[0002] It is often necessary to open metal housings that house internal wires to make electrical connections to outside wiring. Many such housings have removable access plates, but many do not. Furthermore, the use of these access plates requires that the access plates comply with UL certification requirements. The size of the plate and its removal (and replacement) often do not allow for easy access to make the desired connection(s). This is especially true in suspended or restricted-access locations on the housing. Thus, in many situations, disassembly of the housing is required. Summary of the Invention [Problem to be solved by the invention]

[0003] The present invention overcomes these problems in the prior art because there is no longer a need for an access plate. Thus, by removing a portion from the housing assembly, the structure of the housing is saved and the above-mentioned difficulties in its use are avoided. Furthermore, the wire manager function performed by the inside of the knock-out plug not only allows quick access to the internal wires, but also presents these wires in an organized manner. [Means for solving the problem]

[0004] The present invention applies generally to metal housings that house electrical wiring, but is described below as applied to indoor lighting fixtures. The invention is not so limited, as any metal housing requiring external access to one or more of its internal wires is contemplated by the present invention.

[0005] As will be explained below, one aspect of the invention includes a wire retention device inside a knock-out plug positioned in the lighting fixture housing. The size of this device and the positioning of the wire attached to it allows it to be pulled through the resulting hole when the knock-out plug is removed, thus providing easy access to the wire for making / changing wire connections.

[0006] Another aspect of the present invention establishes a wire management system incorporating a wire retention device.

[0007] Once the desired connections to the external wires have been made, a further aspect of the present invention allows a conventional clamping device to be employed to secure the external wires to the lighting fixture and close up the plug hole to comply with UL certification requirements. [Brief explanation of the drawings]

[0008] Further details, aspects and embodiments of the present invention will now be described, by way of example only, with reference to the drawings in which elements are illustrated for simplicity and clarity and are not necessarily drawn to scale. In the figures, elements corresponding to elements already described may have the same reference numerals. [Figure 1A] 1 shows a luminaire housing 100 according to one embodiment of the present invention. [Figure 1B] 1 shows an access knockout plug 104 according to the present invention. [Figure 2] FIG. 1 shows an internal view of the lighting fixture showing the knockout access plug. [Figure 3] A side perspective view of the hook device 202 of the knock-out access plug is shown. [Figure 4] 1 illustrates the use of a hook device in a manufacturing process. [Figure 5] 1 illustrates the use of a hook device in the installation process. [Figure 6] 1 illustrates the use of a knock-out access plug, where removal of the plug allows access to the internal wires. [Figure 7] 1 illustrates the use of a knock-out access plug, where removal of the plug allows access to the internal wires. DETAILED DESCRIPTION OF THE INVENTION

[0009] While the invention is susceptible to embodiment in many different forms, one or more specific embodiments have been shown in the drawings and are herein described in detail, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments shown and described.

[0010] In the following, elements of an operational embodiment are described for the sake of understanding, however, it will be apparent that each element is configured to perform the functions described as being performed by it.

[0011] Furthermore, the invention is not limited to these embodiments, but rather the invention lies in each and every novel feature or combination of features described herein or recited in different dependent claims.

[0012] FIG. 1A illustrates a luminaire housing 100 according to one embodiment of the present invention. The luminaire housing 100 can have two end walls / faces 110 and one or more side walls / faces 112, such as side walls to form a rectangular housing box. FIG. 1B illustrates a close-up view of a conventional knockout plug 102 in a luminaire housing and an access knockout plug 104 according to the present invention. As described further below, the access knockout plug includes a hook device 202 therein that is used to attach the luminaire's internal wires. In one embodiment of the present invention, the access knockout plug is positioned in a luminaire housing orifice that includes a square cut edge 106. This square cut edge allows for the introduction of a screwdriver or similar device to more quickly remove the access knockout plug from outside the luminaire without disturbing or damaging the wires attached to the hook.

[0013] Also shown in the embodiment depicted in Figure 1B is a label 108 identifying the location of the access knock-out plug. In this embodiment, the wording is general in nature, reading "CONNECTION WIRES HERE." In other embodiments, specific connection wires may be identified.

[0014] 2 is an internal view of a light fixture showing knockout access plug 104 and a conventional knockout plug 102 as viewed from inside the light fixture. As shown in this embodiment, knockout access plug hook device 202 consists of a cantilevered device that is integral with knockout access plug 104.

[0015] Figure 3 shows a side perspective view of hook device 202. In a preferred embodiment of the invention, hook device 202 is formed by lancing the metal side of light fixture housing 101 and bending the cut material to form hook device 202 of Figure 2. In this manner, the knock-out access plug and its hook device 202 are formed from the sheet metal material of the light fixture housing. Thus, no additional material is required in the manufacture of a light fixture including the knock-out access plug of the claimed invention.

[0016] Figure 4 illustrates the use of a hook device in the manufacturing process. In the illustrated embodiment, one or more internal wires 402 are pressed into the hook via a snap-like feature 404 near the end of the hook. For thinner, more flexible wires, a loop may be formed with the wire(s) around the hook, as shown, thereby securing the wire and preventing it from falling off the hook. For thicker internal wires 402, forming such a loop may not be necessary, as the shape and resilience of the access plug hook (as illustrated in Figure 5) is sufficient to secure the wire.

[0017] 6 and 7 illustrate the use of the present invention in an installation process. A screwdriver or similar device (not shown) is inserted into the square-cut edge of the knockout access plug orifice 106 to initiate removal of the plug. Once the knockout access plug is removed, the wires attached to its hooks are pulled out of the luminaire, allowing easy access to the internal wires. Once modification(s) to these wires and / or connection(s) to external wires are complete, the wires can be secured to the luminaire housing with any well-known connection device that encloses the knockout access plug hole 702 to comply with UL certification requirements.

[0018] The foregoing detailed description has illustrated some of the many forms the invention can take. The above examples are merely illustrative of some possible embodiments of various aspects of the invention, and equivalent modifications and / or alterations will occur to others skilled in the art upon reading and understanding this invention and the accompanying drawings. In particular, with regard to the various functions performed by the components (devices, systems, etc.) described above, the terms used to describe such components (including references to "means") are intended, unless otherwise indicated, to correspond to any component, such as hardware or combination of hardware, that performs the specified function of the described component (i.e., is functionally equivalent) even if it is not structurally equivalent to the disclosed structure that performs that function in an illustrated implementation of the disclosure.

[0019] Although particular features of the invention have been illustrated and / or described with respect to only one of several implementations, such features may be combined with one or more other features of other implementations as may be desirable and advantageous for any given or particular application. Further, unless expressly stated otherwise, reference to a singular component or item is intended to encompass two or more such components or items.

[0020] The indefinite articles "a" and "an," as used in the specification and claims, should be understood to mean "at least one" unless clearly indicated otherwise. The word "and / or," as used in the specification and claims, should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are present conjunctively in some cases and disjunctively in other cases. Multiple elements listed with "and / or" should be construed in the same manner, i.e., "one or more" of the elements so conjoined. Other elements other than the elements specifically identified by the "and / or" clause may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to "A and / or B," when used with open-ended language such as "comprising," can refer in one embodiment to A only (optionally including elements other than B), in another embodiment to B only (optionally including elements other than A), in yet another embodiment to both A and B (optionally including other elements), etc.

[0021] As used 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" or "and / or" shall be construed as inclusive, i.e., including at least one, but also two or more of several elements or lists of elements, and optionally including additional unlisted items. Only terms such as "only one of" or "exactly one of," or when used in the claims, "consisting of," where the contrary is clearly indicated, refer to the inclusion of exactly one of several elements or lists of elements. In general, the term "or," as used herein, shall be construed as indicating exclusive alternatives (i.e., "one or the other, but not both") only when preceding terms of exclusivity, such as "any of," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0022] As used in this specification and claims, the phrase "at least one," referring to a list of one or more elements, should be understood to mean at least one 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 combinations of elements in the list of elements. This definition also allows for elements other than those specifically identified in the list of elements to which the phrase "at least one" refers, may optionally be present, whether related or unrelated 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 to, in one embodiment, at least one A, optionally including more than one, and no B (and optionally including elements other than B); in another embodiment, at least one B, optionally including more than one, and no A (and optionally including elements other than A); in yet another embodiment, at least one A, optionally including more than one, and at least one B (and optionally including other elements), optionally including more than one;

[0023] It should also be understood that, unless expressly indicated otherwise, in any method claimed herein that includes more than one step or action, the order of the method steps or actions is not necessarily limited to the order in which the method steps or actions are recited.

[0024] In the claims and the above specification, all transitional phrases such as "comprise," "include," "carry," "have," "include," "involve," "hold," "consisting of," and the like, are to be understood to be open-ended, i.e., meaning including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of," respectively, shall be closed or semi-closed transitional phrases as set forth in Section 2111.03 of the U.S. Patent Office Guidelines for Patent Examination.

Claims

1. A housing having an interior space surrounding at least one electrical wire, the housing having one or more wall surfaces, the one or more wall surfaces having at least one metal surface, the metal surface comprising: a metal knockout access plug having an interior side facing the interior space of the housing, the interior side including a hook; During manufacturing of the housing, the at least one electrical wire is attached to the hook; During installation or maintenance of the housing, removal of the access plug provides access to the at least one electrical wire so that the at least one electrical wire can be pulled out of the housing, thereby enabling an electrical connection to be made with one or more external wires.

2. The housing of claim 1 , wherein the hook is formed by cutting and bending the knockout access plug.

3. The housing of claim 2 , wherein the hook is biased away from the interior space of the housing.

4. The housing of claim 1 , wherein the metal surface includes a square cut edge adjacent the knockout access plug to allow removal of the knockout access plug.

5. The housing of claim 3 , wherein the housing is a lighting fixture.

6. The housing of claim 5 , wherein the hook functions as a wire manager for multiple wires within the lighting fixture.

7. 6. The housing of claim 5, wherein removal of the knock-out access plug opens a hole in the housing sized to be surrounded by a conventional cable connection device.

8. 1. A method for providing access to at least one electrical wire housed within an interior space of a housing, the housing having at least one metal surface, the method comprising: forming a metal knockout access plug in the at least one metal surface, the knockout access plug having a hook device on a surface facing the interior space of the housing; attaching the at least one electrical wire to a hook; removing the knock-out access plug pulls the at least one electrical wire out of the housing, thereby providing access to the at least one electrical wire; A method comprising:

9. The method of claim 8 , wherein the forming step includes cutting and bending the knockout access plug.

10. 10. The method of claim 9, wherein the forming step includes bending hooks so that the hooks are biased in a direction away from the interior space of the housing.

11. 10. The method of claim 9, including providing a square cut edge adjacent the knock-out access plug to allow for removal of the knock-out access plug.

12. The method of claim 9 , wherein the housing is a lighting fixture.

13. The method of claim 12 , wherein the hook acts as a wire manager for multiple wires inside the lighting fixture.

14. 13. The method of claim 12, wherein providing access to the at least one electrical wire allows a connection to be made between the at least one electrical wire and a wire external to the housing.

15. 15. The method of claim 14, wherein the removing comprises drilling a hole in the housing, the method including surrounding the hole with a conventional cable connection device that secures external wires to the lighting fixture.

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