Overhead door light power connection system
11404834 · 2022-08-02
Assignee
Inventors
Cpc classification
F21V23/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01R24/28
ELECTRICITY
E05D15/0621
FIXED CONSTRUCTIONS
E06B7/28
FIXED CONSTRUCTIONS
F21V33/006
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
H01R24/76
ELECTRICITY
H01R24/28
ELECTRICITY
F21V23/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E06B7/28
FIXED CONSTRUCTIONS
Abstract
A lighting system for a door having a plurality of wheels that roll in a rail to support the door in an opened configuration and a closed configuration, the rail having an interior bounded by a pair of opposing U-shaped channels, and the system including at least one light attached to the door, a rail contact fixedly mounted in the interior of the rail, a door contact mounted on the door and electrically connectable to the at least one light, the door contact structured to move entirely within the interior of the rail and to contact the rail contact only in response to the door being in the opened configuration to convey sourced electricity to at least one light to illuminate the light in response to the door contact making electrical contact with the rail contact when the door is in the opened position.
Claims
1. A kit for illuminating a room having a power source, the illumination of the room taking place when a door, mounted on a rail having an interior defined by opposing U-shaped channels, is completely opened, the kit comprising: a two-part contact switch comprising: a plug assembly structured to be connected to one member of a connection set consisting of the door and a structure connected to the door and to reside entirely in the interior of the channel of the rail, the plug assembly having a pair of electrical contacts extending therefrom; and a receptacle assembly having an electrically conductive contact surface and configured to be mounted on one member of a mounted set consisting of a door track railing, a door opener track, and operator system; wherein the receptacle assembly is sized and shaped to reside entirely in the interior of the channel of the rail; a light structured to be electrically connected to one of the plug assembly and receptacle assembly and to be mounted on an inside surface of the door; and wherein when the door is completely opened, the pair of electrical contacts extending from the plug assembly make electrical contact with the electrically conductive contact surface in the receptacle assembly to complete an electrical circuit through the pair of electrical contacts and the contact surface that powers the light and in turn illuminates the room.
2. The kit for illuminating the room of claim 1, wherein the plug assembly is structured to be attached to the door and to move within the interior of the rail in response to movement of the door, and the receptacle assembly is structured to be fixedly attached inside the interior of the rail and in alignment with the plug assembly.
3. The kit for illuminating a room of claim 1, wherein the pair of electrical contacts in the plug assembly comprise a pair of electrical prongs extending from a nose and the receptacle assembly has a recessed area to receive the electrical prongs and the nose of the plug assembly in slidable engagement.
4. A kit for use in illuminating a room in response to a door being moved to an opened condition and in extinguishing illumination of the room in response to the door being moved out of the opened condition, the door mounted on a door track system that includes a rail having an interior defined by two opposing U-shaped channels, the kit comprising: a two-part contact switch that includes: a door contact connectable to the door and sized and shaped to entirely reside in and move within the interior of the rail, the door contact having two electrical contacts; and a rail contact having a contact surface and configured to be fixedly attached to and reside entirely within the interior of the rail, wherein the two electrical contacts are structured to contact the rail contact in response to the door being moved to the opened condition and complete an electric circuit that includes the two electrical contacts and the rail contact to illuminate the light.
5. A lighting system, comprising: a door having a plurality of wheels; a rail structured to receive the wheels in rolling engagement and to support the door in an opened configuration and a closed configuration, the rail having an interior bounded by a pair of opposing U-shaped channels; at least one light attached to the door; a rail contact fixedly mounted to and residing entirely within the interior of the rail; a door contact mounted on the door and electrically connectable to the at least one light, the door contact structured to reside entirely within and to move within the interior of the rail and to contact the rail contact only in response to the door being in the opened configuration; a power adaptor electrically connected to the rail contact and structured to convey sourced electricity to the at least one light via the rail contact and the door contact to illuminate the light in response to the door contact making electrical contact with the rail contact when the door is in the opened position.
6. The lighting system of claim 5 wherein the one of the rail contact and the door contact comprises a pair of electrically conductive prongs, and wherein the other of the rail contact and the door contact comprises an electrically conductive contact plate.
7. The lighting system of claim 5 wherein the rail contact is positioned on the rail to be in alignment with the door contact to receive the door contact in slidable engagement and in electrical contact when the door is in the opened configuration.
8. A kit for illuminating a room having a power source, the illumination of the room taking place when a door, mounted on a rail having an interior defined by opposing U-shaped channels, is completely opened, the kit comprising: a two-part contact switch comprising: a plug assembly structured to be connected to one member of a connection set consisting of the door and a structure connected to the door and to reside in the interior of the channel of the rail, the plug assembly having a pair of electrical prongs extending from a nose and the receptacle assembly has a recessed area to receive the electrical prongs and the nose of the plug assembly in slidable engagement; and a receptacle assembly having a contact surface and configured to be mounted on one member of a mounted set consisting of a door track railing, a door opener track, and operator system; wherein the receptacle assembly is sized and shaped to reside in the interior of the channel of the rail; a light structured to be electrically connected to one of the plug assembly and receptacle assembly and to be mounted on an inside surface of the door; and wherein when the door is completely opened, the plug assembly makes contact with the receptacle assembly to complete a circuit that powers the light and in turn illuminates the room.
9. The kit for illuminating the room of claim 8, wherein the plug assembly is structured to be attached to the door and to move within the interior of the rail in response to movement of the door, and the receptacle assembly is structured to be fixedly attached inside the interior of the rail and in alignment with the plug assembly.
Description
DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(1) The foregoing and other features and advantages of the present disclosure will be more readily appreciated as the same become better understood from the following detailed description when taken in conjunction with the accompanying drawings, wherein:
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DETAILED DESCRIPTION
(12) The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary implementations of the disclosure are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the implementations set forth herein. Rather, these implementations are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like reference numerals refer to like elements throughout.
(13) The terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” or “includes” and/or “including” or “has” and/or “having” when used herein, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.
(14) Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
(15) As used herein, “around,” “about” or “approximately” shall generally mean within 20 percent, preferably within 10 percent, and more preferably within 5 percent of a given value or range. Numerical quantities given herein are approximate, meaning that the term “around,” “about” or “approximately” can be inferred if not expressly stated. Also, as used herein, the term “plurality” means a number greater than one.
(16) This present disclosure is an improved, low voltage power connector for an overhead door light, such as an overhead door light described in applicants' prior U.S. Pat. Nos. 9,832,843 and 10,342,098). It should be noted that the problem of blockage of a room or large vehicle overhead light can occur whether or not an overhead door is manually or automatically opened and closed. The kit and system disclosed herein serves any overhead door—manual or automatic—with a suitable source of low voltage power sufficient to power a light or lights. The phrase “low voltage,” in this context, is defined as 0-49 volts—a voltage low enough such that risk of human electrical shock is minimal.
(17) Often, overhead door lights, whether for a home garage door or a business or vehicle overhead door, are installed as an aftermarket item. Simplicity of installation is an important feature, as the process is often performed by untrained personnel. Simplicity of installation is one of the objects of this disclosure.
(18) And while garage door mechanical linkages, automatic door opener systems, and LED panel lights have been in use for many years, with many of the functional problems worked out for these systems over that time, an unreliable power connection is a common failure mode for lighting systems attached to the inside surface of a movable door. Reliability of service with minimal maintenance is another object of this disclosure.
(19) Many garages, warehouses, delivery trucks, and other potential settings for an interior overhead door light are often filled with merchandise, tools, stored materials, etc., that may clutter the area immediately above and around a door that opens and closes regularly. Movement of the door can cause shifting of this clutter and can interfere with the door's function, and can damage the door or portions thereof. Another object of this disclosure is to reduce the overall size of the power connection portion of an overhead door light, and to locate the male (or plug) and receptacle (or socket) portions of the power connector within or immediately around the supporting rails common to most overhead doors, thus minimizing the risk of knocking out of alignment and damaging the two power connectors.
(20) As will be described more fully below, the present disclosure provides a design and system that permits the user to attach the power connector to either of the two rails typically used to guide and support overhead doors.
(21) Generally, the lighting system includes a door having a plurality of wheels, a rail structured to receive the wheels in rolling engagement and to support the door in an opened configuration and a closed configuration, the rail having an interior bounded by a pair of opposing U-shaped channels, at least one light attached to the door, a rail contact fixedly mounted in the interior of the rail, a door contact mounted on the door and electrically connectable to the at least one light, the door contact structured to move within the interior of the rail and to contact the rail contact only in response to the door being in the opened configuration, and a power adaptor electrically connected to the rail contact and structured to convey sourced electricity to the at least one light via the rail contact and the door contact to illuminate the light in response to the door contact making electrical contact with the rail contact when the door is in the opened position.
(22) In one implementation a kit is provided that generally includes the components to be described more fully below. More particularly, a kit is provided for use in illuminating a room in response to a door being moved to an opened condition and in extinguishing illumination of the room in response to the door being moved out of the opened condition is provided. The door is mounted on a door track system that includes a rail having an interior defined by two opposing U-shaped channels. The kit includes a two-part contact switch that includes a door contact connectable to the door and sized and shaped to reside in and move within the interior of the rail, the door contact switch having at least one contact surface, and a rail contact having a contact surface and configured to be fixedly attached to the interior of the rail, wherein the door contact is structured to contact the rail contact in response to the door being moved to the opened condition and complete an electric circuit to illuminate the light.
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(25) As shown in
(26) The mounting of the receptacle assembly on the rail 26, particularly in the interior 32 of the rail 26, is easier, offers more reliable alignment, and better protection from accidental damage, than attaching a power connector box to the rail with adjustable clamps, screws, bolts, or adhesives, as known designs require.
(27) In
(28) Also shown in
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(30) A preferred implementation uses a magnet 48, whether held by a protrusion 46 and rolling directly along the interior 32 of the rail 26, or inserted within the plug assembly's 24 structure (but without direct contact to the metal of the rail, to avoid frictional wear of the magnet), to hold the movable plug assembly 24 in close proximity to the upper corner of the rail
(31) Note also that the plug 40 need not be associated with the moving door, and the receptacle need not be associated with a stable rail attachment. The plug 40 and receptacle 42 could be switched in their mounting positions so that the plug assembly 24 is attached to the rail 26 and the receptacle assembly 34 is attached to the door 22. Or such designations could be made moot with use of coaxial or other power connector options. It will be appreciate from the foregoing that the present disclosure uses the overhead door rails to contain, protect, and guide the plug 40 (or receptacle 42 as the case may be) with a low voltage, indoor system. This differs from other overhead door light power connectors, which are typically associated with the moving door in a more exposed, complicated, expensive, and less reliable method.
(32) As will be appreciated from the foregoing, the plug assembly 24 and the receptacle assembly 34 both reside entirely in the interior 32 of the rail 26. The interior 32 is bounded by the two opposing U-shaped channels, each channel described below as a U-shaped roller alignment channel 128. Having both the plug assembly 24 and receptacle assembly 34 mounted entirely within the interior space 32 of the rail 26 provides protection for these two components and facilitates installation. For example, the clamp 36 can be a well-known hose clamp that encircles the rail 26 and the receptacle component 34. This type of attachment simplifies installation while permitting easy adjustment in the position of the receptacle assembly 34 relative to the plug assembly 24 when the door is in the fully opened configuration.
(33) Some other possible designs are shown below and illustrated in the accompanying drawings.
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(35) Preferably the nose 114 and prongs 112 are guided into the plug assembly by having the receptacle indented inside the receptacle assembly 118, which leads to metal sockets (not shown) and thereafter to wires 126 that connect to a power supply (not shown), such as a building's 120 volt AC supply.
(36) Instead of a magnet as shown in design versions depicted in illustrations above, the plug assembly 104 shown in
(37) For example,
(38) a) the hardware that connects the roller and axle assembly to the door, and
(39) b) the roller itself.
(40) Overhead door support rails are not always in perfect alignment. As a door opens and closes, the gap between door and support rollers will change over the course of the door's travel. The addition of the bushing 132, snapped over the topmost door support roller's axle between the roller and the door hardware, insures a reliable gap, and prevents pinching and excessive wear of a plastic or soft metal plug assembly of the plug and receptacle assembly that would otherwise occur around the opening 108.
(41) In
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(44) a) a receptacle 124 or socket portion (in this example) that is firmly set into the proper position relative to the rail 166 (“full-open” door position), and
(45) b) a plug assembly 150 that has a predictable path relative to the rail and the moving door. No other X/Y/Z variables (horizontal (X and Z) and vertical (Y)) need to be compensated for with the present design.
(46) The use of an open yolk 162 to install the plug assembly 150 to an overhead door's topmost roller axle is easier and requires less time than removing the roller and axle to install the plug assembly 150, as would be necessary in the assemblies shown in
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(49) This method of installing the male connector to the door is easier than removing the roller/axle, which would be necessary in the assemblies shown in
(50) The various implementations described above can be combined to provide further implementations. Aspects of the implementations can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further implementations.
(51) These and other changes can be made to the implementations in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific implementations disclosed in the specification and the claims, but should be construed to include all possible implementations along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.