DUAL EXTRUSION SYSTEM FOR LED LIGHT FIXTURE

Abstract

A dual extrusion system for an LED light fixture comprises a first extrusion and a second extrusion. The first extrusion has a channel shape and dimensioned to enable underground installation. The first extrusion includes a gutter on an exterior surface, used for connecting multiple first extrusions. The first extrusion also includes multiple flanges on either side of the exterior for stabilizing first extrusion in the ground. The first extrusion also includes interior flanges on either side for providing a floor to receive the second extrusion. The system also provides a second extrusion comprising a channel that is placed within the first extrusion. The second extrusion includes free edges extending along a top brim. Free edges hold a plastic cover. The second extrusion also includes exterior flanges for engaging with interior flanges of first extrusion. The second extrusion also has flanges that create a floor to retain LED strips.

Claims

1. A dual extrusion system for LED light fixture, the system comprising: a) a first extrusion comprising a channel configured to be placed within the ground, the first extrusion comprising: at least one gutter disposed on an exterior surface of the first extrusion, the at least one gutter configured to connect two instances of the first extrusion; at least two flanges on either side of the exterior surface, the at least two flanges configured for engaging with the ground around the at least two flanges; and at least two interior flanges on either side of an interior surface of the first extrusion, the at least two interior flanges configured for providing a floor for a second extrusion; b) the second extrusion comprising a channel configured to be placed within the first extrusion, the second extrusion comprising: multiple free edges disposed along a top brim, the free edges configured for holding a plastic cover; at least two exterior flanges on either side of an exterior surface of the second extrusion, the at least two exterior flanges of the second extrusion configured for engaging with the at least two interior flanges of the first extrusion, so as to secure the second extrusion within the first extrusion; and at least two LED flanges on either side of an interior surface of the second extrusion, the at least two LED flanges of the second extrusion configured for providing a floor for an LED strip.

2. The system of claim 1, wherein the first extrusion comprises an aluminum material.

3. The system of claim 1, wherein the second extrusion comprises an aluminum material.

4. The system of claim 1, wherein the first extrusion has a first length that is longer than a second length of the second extrusion.

5. The system of claim 1, wherein the channel of the first extrusion defines a U-shaped configuration.

6. The system of claim 1, wherein the channel of the second extrusion defines a U-shaped configuration.

7. The system of claim 1, wherein the at least two exterior flanges of the second extrusion define a sloped disposition.

8. The system of claim 1, wherein the at least two LED flanges are disposed horizontally relative to the longitudinal of the second extrusion.

9. The system of claim 1, further comprising a circuitry operatively connected to the LED strip.

10. The system of claim 1, wherein the at least one gutter defines a circular shape.

11. The system of claim 1, wherein the channels of the first and second extrusions form multiple fastening holes configured to enable passage of at least one fastener.

12. The system of claim 11, wherein the fastening holes are configured to enable connecting the first extrusion to the second extrusion.

13. The system of claim 12, further comprising at least one bracket configured to help align the first extrusion with the second extrusion.

14. The system of claim 12, further comprising at least one end plate configured to fasten to the termini of the connected first and second extrusions.

15. The system of claim 11, further comprising a fastening tool configured to introduce the at least one fastener into the fastening holes.

16. A dual extrusion system for LED light fixture, the system comprising: a) an aluminum first extrusion comprising a U-shaped channel configured to be placed within the ground, the channels of the first extrusion forming multiple fastening holes configured to enable passage of at least one fastener, the first extrusion comprising: at least one gutter disposed on an exterior surface of the first extrusion, the at least one gutter configured to connect two instances of the first extrusion; at least two flanges on either side of the exterior surface, the at least two flanges configured for engaging with the ground around the at least two flanges; and at least two interior flanges on either side of an interior surface of the first extrusion, the at least two interior flanges configured for providing a floor for an aluminum second extrusion; b) the aluminum second extrusion comprising a U-shaped channel configured to be placed within the first extrusion, the channels of the second extrusion forming multiple fastening holes configured to enable passage of at least one fastener, the second extrusion comprising: multiple free edges disposed along a top brim, the free edges configured for holding a plastic cover; at least two exterior flanges on either side of an exterior surface of the second extrusion, the at least two exterior flanges of the second extrusion configured for engaging with the at least two interior flanges of the first extrusion, so as to secure the second extrusion within the first extrusion; at least two LED flanges on either side of an interior surface of the second extrusion, the at least two LED flanges of the second extrusion configured for providing a floor for an LED strip; c) a circuitry operatively connected to the LED strip; d) at least one bracket configured to facilitate aligning the first extrusion with the second extrusion; and e) at least one end plate configured to fasten to a termini of the first and second extrusions.

17. The system of claim 16, wherein the first extrusion has a first length that is longer than a second length of the second extrusion.

18. The system of claim 16, wherein the at least two exterior flanges of the second extrusion define a sloped disposition.

19. The system of claim 16, wherein the at least two LED flanges are disposed horizontally relative to the longitudinal of the second extrusion.

20. A dual extrusion system for LED light fixture, the system consisting of: a) an aluminum first extrusion comprising a U-shaped channel configured to be placed within the ground, the channels of the first extrusion forming multiple fastening holes configured to enable passage of at least one fastener, the first extrusion comprising: at least one gutter disposed on an exterior surface of the first extrusion, the at least one gutter configured to connect two instances of the first extrusion; at least two flanges on either side of the exterior surface, the at least two flanges configured for engaging with the ground around the at least two flanges; and at least two interior flanges on either side of an interior surface of the first extrusion, the at least two interior flanges configured for providing a floor for an aluminum second extrusion; b) the aluminum second extrusion comprising a U-shaped channel configured to be placed within the first extrusion, the channels of the second extrusion forming multiple fastening holes configured to enable passage of at least one fastener, the second extrusion comprising: multiple free edges disposed along a top brim, the free edges configured for holding a plastic cover; at least two exterior flanges on either side of an exterior surface of the second extrusion, the at least two exterior flanges of the second extrusion configured for engaging with the at least two interior flanges of the first extrusion, so as to secure the second extrusion within the first extrusion, the at least two exterior flanges of the second extrusion define a sloped disposition; at least two LED flanges on either side of an interior surface of the second extrusion, the at least two LED flanges of the second extrusion configured for providing a floor for an LED strip, the at least two LED flanges being disposed horizontally relative to the longitudinal of the second extrusion; c) a circuitry operatively connected to the LED strip; d) at least one bracket configured to facilitate aligning the first extrusion with the second extrusion; and e) at least one end plate configured to fasten to a termini of the first and second extrusions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the claimed subject matter and together with the description, serve to explain the principles of the claimed subject matter. The embodiments illustrated herein are presently preferred, it being understood, however, that the claimed subject matter is not limited to the precise arrangements and instrumentalities shown, wherein:

[0015] FIG. 1 illustrates a front view of an exemplary dual extrusion system for an LED light fixture, showing a first extrusion and a second extrusion separated, in accordance with an exemplary embodiment;

[0016] FIG. 2 illustrates a front view of the dual extrusion system for an LED light fixture shown in FIG. 1, showing a first extrusion and a second extrusion coupled together, in accordance with an exemplary embodiment;

[0017] FIG. 3 illustrates a front view of an alternative embodiment of a dual extrusion system for an LED light fixture, showing a first extrusion and a second extrusion separated, in accordance with an exemplary embodiment;

[0018] FIG. 4 illustrates a front view of the dual extrusion system for an LED light fixture shown in FIG. 3, showing a first extrusion and a second extrusion coupled together, in accordance with an exemplary embodiment;

[0019] FIG. 5 illustrates a front view of an exemplary circuitry for an LED strip, in accordance with an exemplary embodiment;

[0020] FIG. 6 illustrates a blow-up view of an exemplary dual extrusion system for an LED light fixture, in accordance with an exemplary embodiment;

[0021] FIG. 7 illustrates a perspective view of an exemplary circuitry connected to an LED strip, in accordance with an exemplary embodiment;

[0022] FIG. 8 illustrates a perspective view of an exemplary first extrusion with attached bracket, in accordance with an exemplary embodiment;

[0023] FIG. 9 illustrates a front view of the first extrusion, showing a fastening tool introducing a fastener into the extrusion, in accordance with an exemplary embodiment;

[0024] FIG. 10 illustrates a perspective view of the first extrusion and the second extrusion aligned for coupling together, showing a fastening tool introducing a fastener into the extrusion, in accordance with an exemplary embodiment;

[0025] FIG. 11 illustrates a front view of the first and second extrusions being fastened together, in accordance with an exemplary embodiment;

[0026] FIG. 12 illustrates a perspective view of the first extrusion and second extrusions coupled together, in accordance with an exemplary embodiment;

[0027] FIG. 13 illustrates a perspective view of the first extrusion being introduced below the surface of the ground, in accordance with an exemplary embodiment;

[0028] FIG. 14 illustrates a perspective view of the first extrusion and the second extrusion in the ground and operational with the LED strip extending therefrom, in accordance with an exemplary embodiment;

[0029] FIG. 15 illustrates a sectioned side view of the first extrusion and the second extrusion in the ground with the LED strip extending therefrom, in accordance with an exemplary embodiment;

[0030] FIG. 16 illustrates a front view of the circuitry being aligned for introduction into the sidewalls of the second extrusion, in accordance with an exemplary embodiment;

[0031] FIG. 17 illustrates a front view of the circuitry being introduced into the sidewalls of the second extrusion, in accordance with an exemplary embodiment;

[0032] FIG. 18 illustrates a front view of the circuitry fully installed into the sidewalls of the second extrusion, in accordance with an exemplary embodiment; and

[0033] FIG. 19 illustrates a sectioned side view of the first extrusion and the second extrusion in the ground and operational, in accordance with an exemplary embodiment.

[0034] Like reference numerals refer to like parts throughout the various views of the drawings.

DETAILED DESCRIPTION

[0035] The disclosed embodiments improve upon the issues identified within the prior art by providing a system that allows for quick and easy installation of an LED lighting fixture in the ground, due to the use of a dual extrusion system. Additionally, the dual extrusion system of the claimed embodiments allow for efficient and speedy maintenance and upkeep of the device, since only the top extrusion need be opened and/or removed for proper maintenance. Also, the dual extrusion system of the claimed embodiments provide a space for securely retaining the LED strip and associated circuitry. Therefore, the disclosed embodiments reduce the time necessary for installing said LED lighting fixtures in the ground, as well as the maintenance thereof. The disclosed embodiments also facilitate an easier and less arduous installation and maintenance process.

[0036] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper,” “lower,” “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the claimed embodiments as oriented in the figures. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Specific dimensions and other physical characteristics relating to the embodiments disclosed herein are therefore not to be considered as limiting, unless the claims expressly state otherwise.

[0037] A dual extrusion system for LED light fixture is referenced in FIGS. 1-19. The dual extrusion system for LED light fixture, hereafter “system” provides a unique lighting design having two extrusions in a stacked arrangement, and partially buried underground while retaining an LED strip. The system includes a first aluminum extrusion configured to be placed at least partially below the ground, and a corresponding second aluminum extrusion residing inside the first extrusion, and retaining an LED light fixture inside. The first and second extrusions include an aesthetic arrangement of channels, flanges, gutters, and free edges that work together to mount under the ground, while also securely retaining electrical circuitry 500 and an LED strip 602 that illuminates from within the extrusions.

[0038] As referenced in FIG. 1, the system comprises a first extrusion 102 and a corresponding second extrusion 116. The first extrusion 102 is configured to provide a supportive framework beneath the ground; and the second extrusion resides inside the first extrusion in a stacked relationship, while also retaining an LED strip and associated circuitry. For example, FIG. 2 shows the second extrusion 116 coupled with the first extrusion 102. In some embodiments, the first extrusion 102 has a first length 200 that is longer than a second length 202 of the second extrusion 116. In one non-limiting embodiment, the first and second extrusions 102, 116 comprise an aluminum material. However, in other embodiments, different materials may be used, including heat dispersing metals and polymers; and rust-resistant materials and coatings.

[0039] Looking again at FIG. 1, the first extrusion 102 defines a channel 104 that is sized and dimensioned for introduction beneath the surface of the ground 132. The channel 104 may form a U-shape. However, in other embodiments, a V-shape, or a square-shape may also be used. The channel 104 has an open face that orients upwardly, away from the ground.

[0040] In other embodiments, the first extrusion 102 comprises at least one gutter 106a, 106b. The gutter may include a pair of opposing gutters 106a, 106b projecting from an exterior surface 108 of the first extrusion 102. In one possible embodiment, the at least one gutter defines a circular shape that is sized and dimensioned to receive a fastener. The at least one gutter is configured to connect two instances of the first extrusion. For example, two adjacent first extrusions can be tied together in a lateral arrangement through use of the gutter.

[0041] In some embodiments, the first extrusion 102 also comprises at least two flanges 110a, 110b, 110c, 110d that are disposed on either side of the exterior surface 108. The at least two flanges 110a-d are configured for engaging with the ground 132, around the at least two flanges 110a-d. Because the first extrusion is configured to be partially buried under the ground 132, the flanges 110a-d project laterally from the first extrusion to provide lateral stability, anchoring into the ground 132.

[0042] The first extrusion 102 also comprises at least two interior flanges 112a, 112b that project out from either side of an interior surface 114 of the first extrusion. The at least two interior flanges 112a-b are configured for providing a floor for a second extrusion 116. The interior flanges 112a-b sloped upwardly to prevent the second extrusion 116 from slipping off the first extrusion 102. In alternative embodiments, a non-slip layer (not shown) can be placed on the interior flanges 112a-b to restrict slippage by the second extrusion 116.

[0043] As discussed above, a second extrusion 116, having generally smaller dimensioned than the first extrusion 102, resides inside the channel 104 of the first extrusion. Similar to the first extrusion 102, the second extrusion 116 forms a channel 118 configured to be placed within the first extrusion. The channel 118 formed in the second extrusion 116 may have a U-shape to conform to the channel 104 of the first extrusion. However, in other embodiments, a V-shape may also be used.

[0044] In some embodiments, the second extrusion 116 defines multiple free edges 120a, 120b. The free edges 120b form along a top brim 122 of the second extrusion (see FIG. 1). In some embodiments, the free edges 120a-b are configured for holding a plastic cover 600. As shown in FIG. 6, the plastic cover 600 extends along the longitudinal of the second extrusion, resting on the top brim 122. The plastic cover can be a partially transparent cover that allows light from the LED strip 602 to pass, or serves as a color filter.

[0045] In some embodiments, the second extrusion 116 also comprises at least two exterior flanges 124a, 124b projecting from either side of an exterior surface 126 of the second extrusion. In one possible embodiment, the at least two exterior flanges 124a-b of the second extrusion define a sloped disposition. The exterior flanges 124a-b are configured for engaging with the at least two interior flanges 112a-b of the first extrusion. In alternative embodiments, the exterior flanges 124a-b and interior flanges 112a-b interlock in a snap-fit relationship, or through various mechanical fastening means known in the art. In this manner, the second extrusion secures firmly within the channel of the first extrusion.

[0046] In some embodiments, the second extrusion 116 also comprises at least two LED flanges 128a, 128b that project from either side of an interior surface 130 of the second extrusion 116. In one embodiment, the LED flanges are disposed horizontally relative to the longitudinal of the second extrusion. The LED flanges are configured for providing a floor for an LED strip 602 to reside therein. The LED strip allows the system 100 to illuminate from the ground surface, or partially beneath the ground.

[0047] In addition to the aforementioned system 100, the present disclosure also teaches an alternative dual extrusion system 300, shown in FIG. 3. In this system 300, a first extrusion 302 defines substantially smaller dimensions, including a lesser length 200, than disclosed above. As illustrated, the first extrusion 302 is configured to receive, and couple to a second extrusion 316. The first extrusion 302 defines a channel 304 that is configured to be placed within the ground 132. At least two flanges 310a, 310b, 310c, 310d on either side of the exterior surface enable secure placement into the ground.

[0048] In some embodiments, the at least two flanges 310a-d are configured for engaging with the ground for stabilizing the first extrusion 302. And similar to the aforementioned first extrusion 102, the alternative embodiment of the first extrusion 302 comprises at least two interior flanges 312a, 312b on either side of an interior surface 314 for providing a floor for the second extrusion 316. It is significant to note that the gutter 106a, 106b is not utilized in the shorter version of the first extrusion 302.

[0049] Continuing with FIG. 4, the second extrusion 316 fits into the channel 304 of the first extrusion 302. Similar to the first extrusion 302, the second extrusion 316 forms a channel 318 configured to be placed within the first extrusion 302. The second extrusion 316 also comprises at least two LED flanges 328a, 328b on either side of an interior surface 330 of the second extrusion 316. The second extrusion 316 also comprises at least two exterior flanges 324a, 324b on either side of an exterior surface 326 of the second extrusion for engaging with the at least two interior flanges 312a-b of the first extrusion 302.

[0050] Looking now at FIG. 5, the system 100 may also provide a circuitry 500 that is operatively connected to the LED strip. In some embodiments, the circuitry 500 includes wiring, resistors, circuits, and other electronic components known in the art of lighting fixtures. The LED strip can be securely fastened to the sides of the second extrusion 116 in this manner.

[0051] In some embodiments, shown in FIG. 7, the channels 104, 118 of the first and second extrusions form multiple fastening holes 900a, 900b that are sized and dimensioned to enable passage of at least one fastener 600a, 600b. The fastening holes 900a-b are configured to enable connectivity between the first extrusion 102 to the second extrusion 116. The fasteners may include, without limitation, a threaded screw, a bolt, a nail, a magnet, an adhesive, and a mechanical snap-fit means.

[0052] As shown in FIG. 8, a fastening tool 802 may be utilized to introduce the at least one fastener into the fastening holes. The fastening tool 802 can be a screw driver, an Allen wrench, a torque screw, and other fastening means known in the art. The fastening tool 802 rotatably drives the fastener into the side of the channel, through the first and/or second extrusions 102, 116. For example, FIG. 9 illustrates a front view of the first extrusion 102, showing a fastening tool 802 introducing a fastener into the first extrusion 102.

[0053] As FIG. 10 illustrates, the system 100 further comprises at least one bracket 800a, 800b that is configured to help or facilitate aligning the first extrusion 102 with the second extrusion 116. The bracket can be a linear flat bar with apertures that align with the fastening holes 900a-b in the first extrusion 102. This allows for a telescoping relationship between the first and second extrusions 102, 116. Once the extrusions 102, 116 align in this manner, the fastener can be driven through the fastening holes to secure the desired alignment (see FIG. 11). In one possible embodiment, the system comprises at least one end plate 604a, 604b that is configured to fasten to the termini of the connected first and second extrusions. FIG. 12 shows the end plates being installed through fasteners and the fastening tool.

[0054] In operation, the first extrusion 102 is placed on, or below the surface of the ground 132 (FIG. 13). The channel 104 is fitted into the opening in the ground 132, forming a snug relationship therebetween. The exterior flanges 110a-d serve to stabilize the first extrusion horizontal with the ground. Once the first extrusion 102 is established, the second extrusion 116 aligns with the first extrusion, such that both channels 104, 118 align. The second extrusion is then set into the first extrusion 102, forming a unitary light fixture (see FIG. 14).

[0055] FIG. 15 shows a sectioned side view of the system 100 partially buried beneath the ground, showing the LED strip 602 oriented for illuminating from the second extrusion 116. Continuing with the illumination means, the circuitry 500 can be interchanged/replaced while the extrusions 102, 116 is established into the ground 132. FIGS. 16-17 reference the circuitry 500 being introduced into the sidewalls of the second extrusion 116, with FIG. 18 showing the fully installed circuitry 500 and LED strip 602. After the circuitry 500 and LED strip 602 is placed therein, the illumination can be controlled through an electrical switch. Finally, FIG. 19 shows a side sectioned view of the system full installed and operational to illuminate.

[0056] These and other advantages of the claimed embodiments will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.

[0057] Because many modifications, variations, and changes in detail can be made to the described preferred embodiments described herein, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the claimed embodiments should be determined by the appended claims and their legal equivalence.

[0058] Embodiments herein, for example, are described above with reference to block diagrams and/or operational illustrations of methods and systems, according to said embodiments. The functions/acts noted in the blocks may occur out of the order as described. For example, two steps described in succession may in fact be executed substantially concurrently or the steps may sometimes be executed in the reverse order, depending upon the functionality/acts involved.

[0059] While certain embodiments have been described, other embodiments may exist. Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.