Field of the invention

[001 ] The present invention relates to lighting assemblies, which allow such lighting assemblies to be inserted into and held in architectural structures such as hand rails, stairs etc., but can be used in other structures such as walls, ceilings, etc.

Background of the invention

[002] WO2012/000012 published on 5 January 2012, and filed by Klik Systems Australia

Pty Ltd, describes a lighting assembly for installing through a fitting aperture defined by a handrail. This lighting assembly had a retaining element that is removably inserted through the fitting aperture and a body device for providing a light source, the body device having a coupling element releasably engageable to the retaining element. The retaining element is insertable through the fitting aperture and located within the handrail, whereby insertion of the body device through the fitting aperture enables the coupling element to engage the retaining element thereby releasably retaining the body device.

[003] This lighting assembly had numerous components and required considerable installation time and effort.

[004] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention

[005] The present invention provides a lighting assembly for mounting in a fitting aperture, the lighting assembly comprising a sleeve portion and a body portion, the body portion including an engagement end at one end and at end opposite a light aperture from which a light emitting device which can emit light away from the body, the sleeve portion including a shaped end which matches and receives or adjoins the engagement end, the sleeve portion further including two or more leaves extending away from the shaped end, the leaves including gripping formations thereon, the body portion and the sleeve portion including a recess between them when assembled or formed, whereby the leaves are able to move into the recess during assembly to the fitting aperture, and whereby the gripping formations exert a lateral force against an inner rim of the fitting aperture.

[006] The sleeve portion can include, between the gripping formations and the shaped end, an inclined section which assists with initial movement into the recess by the leaves. [007] The sleeve portion and the body portion can each have a generally cylindrical construction.

[008] The sleeve portion can have two, three, four or five leaves.

[009] The body portion can have a central portion with a dimension or diameter which is less than a dimension or diameter of the engagement end, to thereby form the recess to receive the leaves.

[010] The gripping formations can include one or more than one of the following: a knurled formation; a series of parallel ribs; a helical thread; a bevelled or chamfered portion.

[01 1 ] The gripping formations can be formed on a part of a respective leaf which is one of the following: tapered, that is, increasing in thickness in a direction away from the shaped end; inclined.

[012] The body portion can include an outer flange at the light emission end, the outer flange having an outer dimension or diameter which is greater than the outer dimension or diameter of the engagement end.

[013] The outer flange can be adapted to be received in a counter-bored rim around the fitting aperture.

[014] The light emission end can include a shaped surface or profile which matches or complements a surface in which the fitting aperture is formed.

[015] The light emission end of the body portion can include engagement apertures to allow the lighting assembly to be engaged by a tool to install or remove the lighting assembly into or from the fitting aperture.

[016] The body can include engaging formations which are accessed via the engagement apertures.

[017] The lighting assembly can be such that the gripping formation includes a bevelled or chamfered portion wherein said bevelled or chamfered portion is adapted to engage an rim of an aperture in which said lighting assembly is to be assembled, said bevelled or chamfered portion being adapted maintain a bias on or urge said lighting assembly into said aperture in which said lighting assembly is to be assembled.

[018] The sleeve portion and the body portion can be one of the following: manufactured separately and joined or combined together; manufactured as a single integral piece.

[019] The present invention also provides a handrail assembly having a lighting system installed therein, wherein the lighting system is comprised of at least one lighting assembly as described in paragraphs [005] to [019]. [020] The handrail can be one of a thin wall tube or a thick wall tube.

[021 ] The at least one lighting assembly can be positioned within a counterbored aperture in the handrail.

[022] The at least one lighting assembly can be positioned within a straight sided aperture in said handrail, and said at least one lighting assembly sits proud of a surface of said handrail in which the aperture is located.

[023] The hand rail or tube thereof can be one of: a square hollow section; a rectangular hollow section; a cylindrical section, an elliptical section.

Brief description of the drawings

[024] A detailed description of a preferred embodiment or embodiments will follow, by way of example only, with reference to the accompanying figures of the drawings, in which:

[025] Figure 1 illustrates an upper perspective view of a lighting assembly;

[026] Figure 2 illustrates a lower perspective view of the lighting assembly of Figure 1 ;

[027] Figure 3 illustrates an upper perspective view of a sleeve portion of the lighting assembly of Figure 1 ;

[028] Figure 4 illustrates a lower perspective view of the sleeve portion of Figure 3;

[029] Figure 5 illustrates an upper perspective view of the body portion of the lighting assembly of Figure 1 ;

[030] Figure 6 illustrates a lower perspective view of the body portion of Figure 5;

[031 ] Figure 7 illustrates a plan view of the lighting assembly of Figure 1 ;

[032] Figure 8 illustrates a cross section through line VII-VIII in Figure 7;

[033] Figure 9 illustrates an enlarged view of cross section of circled region IX of Figure

8;

[034] Figure 9A illustrates a cross section similar to Figure 8, where the sleeve and body portion are integrally formed;

[035] Figure 10 illustrates the lighting assembly of Figure 1 installed in a thin walled tube;

[036] Figure 1 1 illustrates an enlarged view of the circled region XI of Figure 10;

[037] Figure 12 illustrates the lighting assembly of Figure 1 installed in a thick or heavy walled tube;

[038] Figure 13 illustrates an enlarged view of the circled region XIII of Figure 12; [039] Figure 14 illustrates the lighting assembly of Figure 1 , on first entering a fitting aperture in a heavy walled tube;

[040] Figure 15 illustrates the lighting assembly of Figure 14, midway on entering the fitting aperture in a heavy walled tube;

[041 ] Figure 16 illustrates the lighting assembly of Figure 14, on completing its travel into the fitting aperture in a thin walled tube;

[042] Figure 17 illustrates the lighting assembly of Figure 1 , on first entering a fitting aperture in a thin walled tube;

[043] Figure 18 illustrates the lighting assembly of Figure 17, midway on entering the fitting aperture in a thin walled tube;

[044] Figure 19 illustrates the lighting assembly of Figure 17, on completing its travel into the fitting aperture in a thin walled tube;

[045] Figure 20 illustrates an upper perspective view of a lighting assembly similar to that of Figure 1 ;

[046] Figure 21 is a front view of the assembly of Figure 20;

[047] Figure 22 is a plan view of the assembly of Figure 20;

[048] Figure 23 is a section through XXI ll-XXI 11 of Figure 22;

[049] Figure 24 is a detail view of area XXIV of Figure 23;

[050] Figure 25 illustrates the assembly of Figure 20 being initially pushed into a thin walled handrail,

[051 ] Figure 26 Illustrates the next stage of assembling the assembly of Figure 20 into a thin walled hand rail;

[052] Figure 27 Illustrates the final stage of assembling the assembly of Figure 20 into a thin walled hand rail;

[053] Figure 28 illustrates a detailed view of area XXVIII of Figure 27;

[054] Figure 29 illustrates an underneath perspective view of a sleeve similar to that used in Figure 20, wherein 2 leaves are present;

[055] Figure 30 illustrates an underneath perspective view of a sleeve similar to that used in Figure 20, wherein 3 leaves are present;

[056] Figure 31 illustrates an underneath perspective view of the sleeve used in Figure

20, wherein 4 leaves are present; [057] Figure 32 illustrates an underneath perspective view of a sleeve similar to that of

Figure 31 , wherein 5 leaves are present;

[058] Figure 33 illustrates a light assembly in a straight hole or aperture in a cylindrical or rectangular or square handrail;

[059] Figure 34 illustrates a hand rail assembly having a plurality of light assemblies flush mounted therein.

Detailed description of the embodiment or embodiments

[060] Illustrated in Figures 1 to 6 and Figures 20 to 28 are lighting assemblies 50 for mounting in a fitting aperture 40 (see Figures 10 to 13, and 25 to 28), such as in a handrail or tube 70 or 70' (see figure 33), the lighting assemblies 50 each comprising sleeve portions 10 and a body portions 30. The body portions 30 include an engagement end 30.2 at one end and at end opposite, a light aperture 30.8 from which a light emitting device which can radiate light away from the body portion 30. The sleeve portions 10 include a shaped end 10.2 which matches and receives the engagement end 30.2 to assemble the sleeve portion 10 and body portion 30. The sleeve portion 10 further includes two or more leaves 10.1 , in this case four such leaves 10.1 , which extends away from the shaped end 10.2. The leaves 10.1 , as will be described in more detail later, include gripping formations 10.4 thereon. The body portion 30 and the sleeve portion 10 envelope a recess 5 between them when assembled, whereby the leaves 10.1 are able to move into the recess 5 during assembly of the lighting assembly 50 into the fitting aperture 40, and whereby the gripping formations 10.4 exert a lateral force against an inner surface 40.2 or rim 40.3 of the fitting aperture 40.

[061 ] The sleeve portions 10 include, between the gripping formations 10.4 and the shaped end 10.2, an inclined section 10.5 which assists with initial movement into the recess 5 by the leaves 10.1 . In the case of Figures 1 to 19, the inclined section 10.5 is of the order of 8 degrees to the vertical, so that the inclined section 10.5 is divergent in a top to bottom direction with respect to the figures, but other angles such as between 5 and 20 degrees would also be suitable. In the sleeves of Figures 20 to 32, the inclined section10.5 is of the order of 5 degrees to the vertical so that the inclined section 10.5 is divergent in a top to bottom direction with respect to the figures. However in the sleeves 10 of figures 20 to 32, there is a longer lead-in or taper of the inclined section 10.5, compared to the inclined section10.5 of the sleeves of Figures 1 to 19.

[062] The sleeve portion 10 and the body portion 30 each have a generally cylindrical construction. They are preferably machined from a 316 or a 304 grade of stainless steel, but other manufacturing techniques can be used, as can other materials, depending upon what the fitting aperture 40 is formed in. [063] While the sleeve portions 10 are illustrated as having four leaves 10.1 , it will be readily understood that the sleeve 10 can have two, three, four or five leaves, and possibly more if desired. It will be noted that between adjacent leaves 10.1 , a slot 10.1 1 having an open end at one end and a curved or radiused terminus at the other, to provide stress relief which would otherwise be present if squared corners were present. As is illustrated in Figures 29 to 32, the sleeves are illustrated with two leaves 10.1 in Figure 29, three leaves 10.1 in Figure 30, four leaves 10.1 in Figure 31 and five leaves 10.1 in Figure 32.

[064] In the Figures 1 to 19, the gripping formations 10.4 are illustrated as being a helical thread, so that the lighting assembly 50 is able to be backward compatible and threaded into fitting apertures which have been threaded in the past. Whereas in the embodiment of Figure 20 to 32, the gripping formations 10.4 are formed as bevelled or chamfered ends 10.41 , making the leaves 10.1 , in the direction of top to bottom, being first of diverging formation due to inclined sections 10.5 and then a converging formation due to bevelled or chamfered ends 10.41 . The bevelled or chamfered ends 10.41 are of an angle to the vertical of approx. 13 degrees. The size of this angle can be varied to adjust the inclined plane forces and or friction forces generated to hold the assembly 50 into position in a mounting aperture. The bevelled or chamfered ends 10.41 , by means of the outward force from the resilience or elastic nature of the cantilevered leaves 10.1 , will bear against the inner circumference or rim 40.3 of the holes or apertures 40, such as may be in a hand-rail, so as to be secured into place, and additionally the resilience or elastic nature of the cantilevered leaves 10.1 , is such as to maintain a bias into, or urge the assembly 50 into, the aperture 40.

[065] However, it will be readily understood that the gripping formations 10.4 exert a lateral force against the side wall 40.2 of the fitting aperture 40, by means of the leaves 10.1 working in a cantilever fashion as they bend elastically when moved into the recess 5. It will also be understood that the helical thread or bevelled or chamfered ends 40.1 illustrated can be replaced by a knurled formation or a series of parallel ribs, or any formation which will generated additional friction than if such formations were not present.

[066] The gripping formations 10.4 are formed on the end of a respective leaf 10.1 which is tapered in its thickness as is best illustrated in Figure 9 and 23 or 24. That is, increasing in thickness in a direction away from the shaped end 10.2. Otherwise, the section on which the gripping formation 10.4 is formed can be inclined in a radially outward direction.

[067] The body portion 10 has a central portion 30.1 1 which has a dimension or diameter which is less than a dimension or diameter of the engagement end 30.2, to thereby form the recess 5 to receive the leaves 10.1 .

[068] The body portion 30 and sleeve 10 are assembled by a press fit between them.

That is, the engagement end 30.2 has an outside diameter which provides a press fit tolerance with respect the inner diameter of the shaped end 10.2. Such a press fit will ensure that the two components remain together at all times, during installation and or removal.

[069] The body portion 30 also has an outer flange 30.10 at the light emission end, which has an outer dimension or diameter which is greater than the outer dimension or diameter of the engagement end 30.2.

[070] The outer flange 30.10 adapted by providing a larger outer diameter, so as to be received in a counter-bored rim 40.1 around the fitting aperture 40. This provides the advantage that the outer flange 30.10 prevents the lighting assembly 50 from pushing too far into the fitting aperture 40. Additionally, by making good contact with the rim 40.1 , the article in which the fitting aperture 40 is made, will act as a heat sink to draw away the heat generated by the LED 32 (see Figure 23) in the body 30.

[071 ] The light emission end which includes in this instance an obround aperture 30.8 includes a shaped surface or profile which matches or complements a surface in which the fitting aperture 40 is formed.

[072] The light emission end of the body portion which includes the aperture 30.8 can include engagement apertures 30.6 to allow the lighting assembly 50 to be engaged by a tool to install or remove the lighting assembly 50 into or from the fitting aperture 40. Additionally, the body 30 includes lateral engaging formations 30.7 which are accessed via the engagement apertures 30.6 by the installation/removal tool. While these apertures 30.6 and 30.7 are provided, other or different formations could be provided such as the holes 30.6 may taper or be angled, or sliding dowels could also be provided to allow tools to engage the light assembly 50, in order to extract it. It is important to note that the body 30 cannot be removed from the sleeve 10, to separately take the body 30 out of the fitting aperture 40. They must be removed together.

[073] There are preferably an even number of open slots 10.1 1 , having slot openings

10.3, between the leaves 10.1 , and preferably at least two of the slots 10.1 1 are diametrically opposed on the sleeve 10, so that the engaging formations 30.7 on the body 30, which in this case are laterally extending blind apertures, will upon assembly be generally centrally located with opposed slots 10.1 1 .

[074] The fitting aperture 40 can be formed in any article or location, such a hand rails, other stair components, other architectural structures or furniture etc.

[075] The body 30 includes counter bored cylindrical inner portions 30.3 and 30.4 in which an LED 32 (as illustrated in Figure 23) and its control circuity 31 (also as illustrated in Figure 23) can be mounted.

[076] Illustrated in Figures 14 to 16 is a sequence to illustrate the stages of the assembly of the lighting assembly 50 in a fitting aperture 40 in a thick or heavy wall structure, of the order of 4mm thick, such as a handrail. It will be noted in Figure 14 that the tapered surface 10.5 engages the inner wall 40.2 of the aperture 40, so that continued inward movement pushes the inboard side of the leaves 10.1 will enter into the recess 5, with continued movement forcing the tapered formation on which the gripping formation 10.4 are formed to be wedged into the wall 40.2 of the aperture 40. It will be also noted that the gripping formations 10.4 have a substantial portion of their area in contact with the side wall 40.2 of the fitting aperture 40. Whereas in Figures 17 to 19, which are similar to that of figures 14 to 16, except that the structure in which fitting aperture 40 is formed is a thin walled hand rail (thickness of approx. 1 .5mm), and that as in Figure 19, a much greater area of the gripping formations 10.4 have no contact with the side wall 40.2 of the fitting aperture 40.

[077] Whereas illustrated in Figures 25 to 28 16 is a sequence to illustrate the stages of the assembly of the lighting assembly 50, with bevelled or chamfered ends 10.41 in a fitting aperture 40 in a thin wall structure, of the order of 1 .5mm to 2mm thick, such as a handrail. It will be noted in Figure 25 that the tapered surface 10.5 engages the inner wall 40.2 of the aperture 40, so that continued inward movement pushes the inboard side of the leaves 10.1 so as to enter into the recess 5, with continued movement forcing the tapered formation on which the gripping formation 10.4 is formed to be wedged into the wall 40.2 of the aperture 40, until the high point rim or section 10.42 is passed. It will be also noted that the gripping formations 10.4, by means of bevels or chamfers 10.41 , have what is effectively a line or circumferential contact with inner edge or rim 40.3 of the fitting aperture 40. This line engagement assists to provide, and or maintain, a bias or urging of the assembly 50 of Figures 25 to 28 into the aperture 40, by means of the cantilevered constructions and the elasticity or resilience this provides to the leaves 10.1 .

[078] The lighting assembly 50 constructed as in Figures 25 to 32, can be installed into a thick or heavy walled tube which includes a counterbore 40.1 , or into a non-counterbored aperture 40 in a thin walled tube, as illustrated in Figure 33, such that the outer rim 30.10 remains proud of the tube outer wall, whether a square, rectangular or cylindrical tube. Alternatively, the length of the bevelled or chamfered portion 10.41 can be made longer and or the angle of the bevel or chamfer 10.41 changed as desired depending upon tube and or design requirements. Preferably, the length of the beveled or chamfered portion 10.41 is chosen so as to fit both thin wall and thick wall tubing. The beveled or chamfered portion 10.41 is of the order of some 1 .56mm in slant height, or approx. 1 .5 mm in depth measured parallel to the longitudinal axis of the assembly 50.

[079] The lighting assemblies 50, depending upon where they are used, can be of any appropriate shape or size. However, when used with handrails, where standard diameters may be of the order 32 to 51 millimetres, the diameter of the fitting aperture 40 is generally of the order of 16mm, with the sleeve 10 and body 30 appropriately sized to match. [080] While the above description and Figures illustrate a sleeve 10 and body 30 are generally cylindrical, other shapes could also be used such a square, triangular, octagonal, or any other polygonal shape.

[081 ] The advent of modern manufacturing techniques, such as 3 dimensional printing, of either metals or plastics, will mean that the body 30 and sleeve 10 can be integrally formed in a single manufacturing process, such as illustrated in Figure 9A, so that the recess 5 is appropriately formed.

[082] Illustrated in Figure 34 is a section of a hand rail assembly 100. The section of the handrail assembly 100 is shown as having a lighting system 101 installed therein, and the lighting system 101 is comprised of at least one lighting assembly 50 as described above. The hand rail tube 70 in Figure 34 is illustrated as a thick wall tube which has the assemblies 50 flush with the outer surface of the tube 70, by providing a counterbored aperture 40, as described above. Alternatively, a thin walled tube as illustrated in Figure 33, could be used, where the thin wall has a straight sided aperture 40 though it to mount the assemblies 50. In this case, the flange 30.10 will sit proud of the outer surface of the cylindrical tube 70, or for that matter a square or rectangular hollow section 70', if it were used. If desired the hand rail 100 can be made from tube of any appropriate shape including elliptical.

[083] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of". A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

[084] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[085] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.