Recessed track with dual-phased removable material for mudding and painting

Abstract

A recessed track filling member comprises a base component designed to be inserted in an enclosure of the recessed track adapted to close up the enclosure of the recessed track distant to the opening; and a top component adapted to close up the entire or almost the entire enclosure of the recessed track. The top component is secured to the base component such as when pulled out of the enclosure, the top component breaks loose from the base component, thereby having the base component remaining in the enclosure while providing access to an aesthetic area of the enclosure for finishing steps, e.g., painting. At the end, the base component can also be pulled out to provide full benefit of the recessed track.

Description

RECESSED TRACK WITH DUAL-PHASED REMOVABLE MATERIAL FOR MUDDING AND PAINTINGCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to, or benefit of, US provisional application No. 63 / 566,648, filed March 18, 2024, the specification of which is hereby incorporated herein by reference in its entirety.BACKGROUND(a) Field

[0002] The subject matter disclosed generally relates to recessed tracks for lighting and similar electrical equipment. More particularly, the subject matter disclosed relates to accessories for recessed tracks, methods on installation of recessed tracks, and methods of finishing surfaces to which a recessed track is mounted.(b) Related Prior Art

[0003] Pulled by demand, designers are designing light fixtures that are becoming less and less visible, or in which unesthetic portions are less visible. One solution towards that goal is using recessed tracks. For them to become less visible, the size of the track must be decreased. With recessed tracks mounted to drywalls, the finishing includes mudding and painting the drywall once the recessed track mounted thereto. With the opening of the recessed tracks decreasing in order to lead them to become virtually invisible, and the aesthetic expectations increasing, sensibility to mud penetration in the opening of the recessed tracks and the recessed tracks being visible since not colored uniformly continually increase.

[0004] There is therefore a need for improvements in the field regarding such issues.SUMMARY

[0005] In some aspects, in order to resolve the technical problem of decreasing visibility of the tracks, improving aesthetic, and easing uniform coloring of drywalls with recessed tracks mounted thereto, there has been developed a kit of a recess track and a member to temporarily mount to the recessed track to ease finishing the drywall and the recessed track without risking affecting the functionality of the recessed track.

[0006] In some aspects, the description herein relates to a removable filling member designed to at least partially close up an enclosure, the enclosure having an opening, enclosure side walls, and an enclosure plane extending between and parallel to the enclosure side walls, the removable filling member including: a base component and a top component secured to one another over a securing interface, the base component including a first top wall, the top component including a second top wall, the member having a removable filling member longitudinal plane extending across the base component and the top component, wherein, when the removable filling member is inserted in the enclosure with the removable filling member longitudinal plane superposed to the enclosure plane, the base component is retained in the enclosure with the first top wall at least partially closing up the enclosure distant to the opening, and the second top wall at least partially closing up the enclosure about the opening, wherein the top component is designed to be removable independently from the base component by breaking up a link therebetween at the securing interface, and wherein the base component is designed to be removable from the enclosure once the top component is removed.

[0007] In some aspects, the description herein relates to a removable filling member, wherein at least one of the base component and top component has a regular profile.

[0008] In some aspects, the description herein relates to a removable filling member, wherein the base component is retained in the enclosure by the basecomponent being at least partially compressed between the side walls of the enclosure.

[0009] In some aspects, the description herein relates to a removable filling member, wherein the enclosure side walls are not flat, wherein the base component includes side lips extending away from the member longitudinal plane.

[0010] In some aspects, the description herein relates to a removable filling member, wherein the base component includes side walls with the side lips extending from the side walls.

[0011] In some aspects, the description herein relates to a removable filling member, wherein the side lips are flexible.

[0012] In some aspects, the description herein relates to a removable filling member, wherein the base component includes a bottom wall, side walls, and first longitudinal lips extending from the side walls at a first distance to the bottom wall, and second longitudinal lips extending from the side walls at a second distance from the bottom wall.

[0013] In some aspects, the description herein relates to a removable filling member, where the first and second longitudinal lips are sloped relative to the side walls.

[0014] In some aspects, the description herein relates to a removable filling member, wherein the base component and the top component have a first and a second width, wherein the securing interface has a third width smaller than the first with and the second width.

[0015] In some aspects, the description herein relates to a removable filling member, wherein the link is one of a glue, a mechanical securing mechanism, and resulting from the member having a unitary body.

[0016] In some aspects, the description herein relates to a removable filling member, wherein the second top wall is flat.

[0017] In some aspects, the description herein relates to a removable filling member, wherein the second top wall has a non-flat shape.

[0018] In some aspects, the description herein relates to a removable filling member, wherein the base component includes at least three side lips per side.

[0019] In some aspects, the description herein relates to a removable filling member, wherein the member is made of silicon.

[0020] In some aspects, the description herein relates to a kit including: a track including an enclosure having an opening, enclosure side walls, and an enclosure plane extending between and parallel to the enclosure side walls, the enclosure having an aesthetic area about the opening and an electric area distant to the opening; and an member removable from the track, the member including a base component and a top component secured to one another over a securing interface, the base component including a first top wall, the top component including a second top wall, the member having an member longitudinal plane extending across the base component and the top component, wherein, when the member is inserted in the enclosure with the member longitudinal plane superposed to the enclosure plane, the base component is retained in the enclosure, the first top wall at least partially closes up the electric area, and the second top wall at least partially closes up the enclosure about the opening, wherein the top component is designed to be removable independently from the base component by breaking up a link therebetween, with the base component at least partially protecting the electric area, and wherein the base component is designed to be removable from the enclosure once the top component is removed, providing access to the electric area.

[0021] In some aspects, the description herein relates to a kit, wherein the track is a recessed track including a pair of mounting wings extending aside the opening.

[0022] In some aspects, the description herein relates to a kit, wherein the electric area includes a pair of longitudinal rooms in which extends at least one electric connector.

[0023] In some aspects, the description herein relates to a kit, wherein the electric area in not flat, providing protrusions for the base component to abut against.

[0024] In some aspects, the description herein relates to a kit, wherein the track consists of an extrusion with open extremities.

[0025] In some aspects, the description herein relates to a kit, wherein the member is made of a flexible material, allowing the member longitudinal plane to take a curved shape.

[0026] Features and advantages of the subject matter hereof will become more apparent in light of the following detailed description of selected embodiments, as illustrated in the accompanying figures. As will be realized, the subject matter disclosed and claimed is capable of modifications in various respects, all without departing from the scope of the claims. Accordingly, the drawings and the description are to be regarded as illustrative in nature and not as restrictive and the full scope of the subject matter is set forth in the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

[0028] Fig. 1 is an elevation front cross-section view of a recessed track in accordance with an embodiment;

[0029] Fig. 2 is a perspective view of a portion of a recessed track assembly comprising a recessed end component; a recessed track, and a recessed joint component and a recessed track in accordance with an embodiment;

[0030] Fig. 3 is a perspective partially exploded view of the recessed track assembly of Fig. 2 with the joint component moved away from two recessed tracks in accordance with an embodiment;

[0031] Fig. 4 is a perspective view of the recessed track assembly of Fig. 2 depicting recessed portions and portions mounted to the mounting surface in accordance with an embodiment;

[0032] Fig. 5 is a cross-section view of an member for filling the enclosure of a recessed track in accordance with an embodiment;

[0033] Fig. 6 is a perspective view of a portion of a recessed track with the top component of the member being partially pulled out of the enclosure of the recessed track in accordance with an embodiment;

[0034] Fig. 7 is a cross-section of a portion of a recessed track with an member inserted in the enclosure in accordance with an embodiment;

[0035] Fig. 8 is a cross-section of a portion of a recessed track with an member inserted in the enclosure with only the base component remaining in accordance with an embodiment; and

[0036] Fig. 9 is a cross-section of a portion of a recessed track with the member totally removed in accordance with an embodiment;

[0037] It will be noted that throughout the appended drawings, like features are identified by like reference numerals.DETAILED DESCRIPTION

[0038] The realizations will now be described more fully hereinafter with reference to the accompanying figures, in which realizations are illustrated. The foregoing may, however, be embodied in many different forms and should not be construed as limited to the illustrated realizations set forth herein.

[0039] With respect to the present description, references to items in the singular should be understood to include items in the plural, and vice versa, unlessexplicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Thus, the term "or" should generally be understood to mean "and / or" and so forth.

[0040] Recitation of ranges of values and of values herein or on the drawings are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. The words “about”, “approximately”, or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and / or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the described realizations. The use of any and all examples, or exemplary language (“e.g.,” “such as”, or the like) provided herein, is intended merely to better illuminate the exemplary realizations and does not pose a limitation on the scope of the realizations. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the realizations. The use of the term “substantially” is intended to mean “for the most part” or “essentially” depending on the context. It is to be construed as indicating that some deviation from the word it qualifies is acceptable as would be appreciated by one of ordinary skill in the art to operate satisfactorily for the intended purpose.

[0041] In the following description, it is understood that terms such as "first", "second", "top", "bottom", "above", "below", and the like, are words of convenience and are not to be construed as limiting terms.

[0042] The terms "top", “up”, “upper”, "bottom", “lower”, “down”, “vertical”, “horizontal”, “interior” and “exterior” and the like are intended to be construed intheir normal meaning in relation with normal installation of the product, e.g., the opening of the recessed housings facing downward.

[0043] It should further be noted that for purposes of this disclosure, the term "coupled" means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature, movable or breakable in nature and / or such joining may allow for the flow of electricity, electrical signals, or other types of signals or communication between two members. Such joining may be achieved with the two members, or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or alternatively may be removable or removable in nature.

[0044] In realizations, there are disclosed recessed housings and recessed housing assemblies, wherein the recessed housings can be installed in different orientations, thereby having the opening of the recessed housings typically facing downward, but being possible to face e.g., sideward.

[0045] Referring now to Figs. 1 to 4, a recessed track assembly 100 may be made of a plurality of combined recessed tracks 102. A recessed track 102 according to an embodiment consists in a longitudinal extrusion made of e.g., aluminum that has a length, a width, and an opening 122 extending sideways from a center plane 105 (enclosure plane). The recessed track 102 features on both sides of the opening 122 a mounting wing 132 for mounting the recessed track 102 to a receiving surface, e.g., a gypsum sheet 200, in which a groove 202 has been cut off to receive the recessed track 102. The longitudinal extrusion forms longitudinal rooms 142, 144 extending from a side wall 143, 145 to about under the opening 122. An end wall 147, opposed to the opening 122, joins the side walls 143, 145 to form an enclosure 141.

[0046] Therefore, in other words, the recessed track 102 has an external wall 140 (comprising the walls 143, 145, 146) defining an enclosure 141 and a mouth, aka opening 122, providing access to the enclosure 141. Beyond the top edge of the opening 122, opening side walls 125, extend inward in the enclosure 141 that can be virtually divided in two areas: an aesthetic area 151 (see Fig. 7) about the opening 122; and an electric area 152 (see Fig. 7) farther from the opening 122.

[0047] In a typical realization, installation of the recessed track assembly 100 comprising such recessed tracks 102 is performed by mounting the recessed track assembly 100 into the groove 202 of the gypsum sheet 200, with the mounting wings 132 extending over the space between the edge of the gypsum sheet 200 and the recessed track 102. The recessed tracks 102 are mounted with e.g., screws or double-sided tape, and mudding is set over the mounting wings 132 to such that almost only the opening 122 is visible. At the end, the drywall, comprising the mud covering a portion of the recessed track, is painted.

[0048] For structural references, the recessed track 102 further comprises grooves 136, a magnetic band 138, a Printed Control Board (PCB 163), external recessed 126, electric connectors 156, pins 165, screw holes 134, joint component 175, end component 172, wings 176, connectors 177 & 179, and connection components 182 & 183.

[0049] Referring additionally to Figs. 5 to 9, there is a removable filling member 160 releasably mounted in the recessed track 102. The removable filling member 160 is designed to fill up or almost fill up the whole enclosure 141 such that, at the step of mudding the drywall, the mud will not penetrate in the enclosure 141. More precisely, the removable filling members 160 are made of compressible material. The removable filling members 160 are designed, through compression, to remain in place in the enclosure regardless of the orientation of the recessed tracks.

[0050] According to an embodiment, the removable members 160 are dimensioned to fill the whole depth or almost the whole depth of the enclosure, from the opening edge 155 wherein the external surface of the recessed track 102 change direction from about parallel to the surface it is designed to be mounted to towards the farther portion of the enclosure 141 relative to the opening edge 155. Accordingly, even is pressure is exerted over the member 160 when e.g., mudding, the member 160 will remain about the opening 122 of the enclosure 141.

[0051] According to an embodiment, the removable filling member 160 has sidewalls 166 that have a funnel-like shape with the funnel stem portion 167 close to the base component 162. The widest portion of the of the funnel is designed to spread between the opening edges 155, preventing penetration in the enclosure of dust or other material beyond the opening edges 155.

[0052] The removable filling member 160 comprises two parts: a top component 164 designed to protect the aesthetic area 151 , and a base component 162 designed to protect the electric area 152 located in the enclosure 141. The removable filling member 160 extends according to a longitudinal plane 170 extending across the base component 162 and the top component 164, with the longitudinal place 170 and the center plane 105 being coplanar when the member 160 is mounted to the recess track 102.

[0053] According to one embodiment, the removable filling member 160 is manufactured as a monobloc piece, or unitary member, with a weakness located at the securing interface where there is a joint between the base component 162 and the top component 164. The weakness, such as a thin membrane 168, is designed that when someone pulls the filling from the housing, if they hook only to the top component 164, the membrane 168 will break (tear up) resulting in the top component 164 being pulled out and the base component remaining in the enclosure 141.

[0054] According to another embodiment, the removable filling member 160 is manufactured in two distinct components, the base component 162 and the top component 164, with the components 162, 164 being designed to be releasably secured to each other, for example using glue, using prongs inserted in holes, or other chemical and / or mechanical securing methods for securing them to one another. When manufactured separately, they may be assembled before being inserted in the enclosure 141 or after being inserted in the enclosure 141 , based on e.g., the selected mode used for securing them to each other and based on the selected mode of inserting them in the enclosure 141.

[0055] According to an embodiment, when the top component 164 is removed, the base component 162 features a surface spreading between both sides of the enclosure 141 and at least partially sealing the electric area 152, preventing material to penetrate the electric area 152.

[0056] According to an embodiment, the base component 162 features on each one of its sides 174 facing the sides of the enclosure 141 at least one longitudinal lip 176 that is extending from the side of the base component 162 slightly toward the plane formed by the opening 122. The lips 176 are bendable but provide improved resistance against the base component 162 being pulled out from the enclosure 141. According to an embodiment, the number of lips 176 may be from one (1 ) to e.g., four (4). According to an embodiment, clearance may remain between components of the recessed track 102 and the side 174 of the base component 162 when the base component 162 is inserted in place.

[0057] According to an embodiment, the base component 162 features on each side a lip 178 designed to at least partially penetrate in a cavity being present in the track that is opened generally sideway. The lip 178, by being inserted in the cavity, is designed to retain the base component 162 in place until a pulling force strong enough to have the lip 178 flexed or breaking being applied to the base component 162.

[0058] According to embodiments, the removable filling member 160 can be made of silicon, rubber-based material, or another material that provides electrical insulation and that presents characteristics of compression and / or deformation allowing the removable filling member 160 to be put in place in the recessed track, and to be pulled out without risking creating damages to the recessed track or to exert an excessive pulling force over the recessed track risking to affect the finishing of the surface. According to embodiments, the design of the removable filling member 160 may include cavities, holes, grooves, or other features that may facilitate deformation of the removable filling member 160 for its pull-out phase. According to embodiments, the removable filling member 160 has a regular profile. According to an embodiment, the member has a regular profile when considering surfaces interfacing the enclosure.

[0059] Intended use of the removable filling member 160 follows the following steps.

[0060] First, the recessed track assembly 100 is mounted to a receiving surface, with the member 160 being inserted at the manufacturing process, before installation of the recessed track assembly 100, or following the installation of the recessed track assembly 100 into the enclosure of the recessed track assembly as depicted on Fig. 7. According to embodiments, the recessed track assembly 100 may comprise a plurality of modules, e.g., recessed tracks, having a distinct removable filling member 160 inserted into their enclosure, or a removable filling member 160 may be customized, e.g., in length, in number of sections, etc., to accommodate the recessed track assembly 100.

[0061] Next, once the recessed track assembly 100 is installed, the next step consists in visually levelling the mounting surface. Practically, this step consists in e.g., mudding a drywall to hide unlevelled features, e.g. screws, and surfaces of the mounting wings 132.

[0062] Next step consists in sanding the drywall to get a smooth surface revealing from the remaining dried mudding without visible features that are desired to be hidden.

[0063] Next step consists in pulling the top component 164, depicted on Fig. 6, breaking it free from the base component 162. When done, the aesthetic area 151 of the housing being up to this step being protected from external material, including mud, to penetrate in the aesthetic area 151 , is smooth and clean. If some material has penetrated, for example during the sanding phase, in the aesthetic area 151 , a person can use a rag over the aesthetic area 151 to ensure that no dust or other material remains.

[0064] At this step, the surface is ready to be finished, painted.

[0065] Thus, next step(s) consists in painting the surface of the drywall.Since the aesthetic area 151 is open as depicted on Fig. 8, the paint will penetrate in the aesthetic area 151 and will cover it.

[0066] Next step, when the painting step(s) is / are completed, consists in removing the base component 162 of the removable filling member 160 from the enclosure, resulting in the electric area 152 becoming operable as depicted on Fig. 9.

[0067] Next step, depending on the type of recessed track or lighting type, may include to mount light fixture(s) to the recessed track assembly 100.

[0068] Accordingly, through these steps, a recessed track assembly 100 can be mounted to a receiving surface, e.g., a drywall, with finishing operation being possible to be performed thereto without risking damaging the recessed track assembly 100 while including into the surfaces undergoing finishing the aesthetic area 151 , in other words a portion of the enclosure 141 beyond the opening 122 of the enclosure 141.

[0069] While preferred embodiments have been described above and illustrated in the accompanying drawings, it will be evident to those skilled in the art that modifications may be made without departing from this disclosure. Such modifications are considered as possible variants comprised in the scope of the disclosure.

Claims

CLAIMS:

1. A removable filling member designed to at least partially close up an enclosure, the enclosure having an opening, enclosure side walls, and an enclosure plane extending between and parallel to the enclosure side walls, the removable filling member comprising: a base component and a top component secured to one another over a securing interface, the base component comprising a first top wall, the top component comprising a second top wall, the removable filling member having a removable filling member longitudinal plane extending across the base component and the top component, wherein, when the removable filling member is inserted in the enclosure with the member longitudinal plane superposed to the enclosure plane, the base component is retained in the enclosure with the first top wall at least partially closing up the enclosure distant to the opening, and the second top wall at least partially closing up the enclosure about the opening, wherein the top component is designed to be removable independently from the base component by breaking up a link therebetween at the securing interface, and wherein the base component is designed to be removable from the enclosure once the top component is removed.

2. The removable filling member of claim 1 , wherein at least one of the base component and top component has a regular profile.

3. The removable filling member of claim 1 , wherein the base component is retained in the enclosure by the base component being at least partially compressed between the side walls of the enclosure.

4. The removable filling member of claim 3, wherein the enclosure side walls are not flat, wherein the base component comprises side lips extending away from the removable filling member longitudinal plane.

5. The removable filling member of claim 4, wherein the base component comprises side walls with the side lips extending from the side walls.

6. The removable filling member of claim 4, wherein the side lips are flexible.

7. The removable filling member of claim 3, wherein the base component comprises a bottom wall, side walls, and first longitudinal lips extending from the side walls at a first distance to the bottom wall, and second longitudinal lips extending from the side walls at a second distance from the bottom wall.

8. The removable filling member of claim 7, where the first and second longitudinal lips are sloped relative to the side walls.

9. The removable filling member of claim 1 , wherein the base component and the top component have a first and a second width, wherein the securing interface has a third width smaller than the first with and the second width.

10. The removable filling member of claim 1 , wherein the link is one of a glue, a mechanical securing mechanism, and resulting from the member having a unitary body.

11. The removable filling member of claim 1 , wherein the second top wall is flat.

12. The removable filling member of claim 1 , wherein the second top wall has a non-flat shape.

13. The removable filling member of claim 4, wherein the base component comprises at least three side lips per side.

14. The removable filling member of claim 1 , wherein the member is made of silicon.

15. A kit comprising: a track comprising an enclosure having an opening, enclosure side walls, and an enclosure plane extending between and parallel to the enclosure side walls, the enclosure having an aesthetic area about the opening and an electric area distant to the opening; and a removable filling member, removable from the track, the removable filling member comprising a base component and a top component secured to one another over a securing interface, the base component comprising a first top wall, the top component comprising a second top wall, the member having a removable filling member longitudinal plane extending across the base component and the top component, wherein, when the removable filling member is inserted in the enclosure with the member longitudinal plane superposed to the enclosure plane, the base component is retained in the enclosure, the first top wall at least partially closes up the electric area, and the second top wall at least partially closes up the enclosure about the opening, wherein the top component is designed to be removable independently from the base component by breaking up a link therebetween, with the base component at least partially protecting the electric area, andwherein the base component is designed to be removable from the enclosure once the top component is removed, providing access to the electric area.

16. The kit of claim 15, wherein the track is a recessed track comprising a pair of mounting wings extending aside the opening.

17. The kit of claim 15, wherein the electric area comprises a pair of longitudinal rooms in which extends at least one electric connector.

18. The kit of claim 15, wherein the electric area in not flat, providing protrusions for the base component to abut against.

19. The kit of claim 15, wherein the track consists of an extrusion with open extremities.

20. The kit of claim 15, wherein the member is made of a flexible material, allowing the member longitudinal plane to take a curved shape.

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