Reflector mounting arrangement and method and clip for mounting a reflector in a fluorescent light fixture

[0001] This invention concerns mounting of reflectors in fluorescent light fixtures. The ability to improve the efficiency of light fixtures has led to adding reflectors above fluorescent light tubes to increase the output of light to save electrical power.

[0002] A typical installation comprises fixing a metal reflector to the fixture housing with fasteners, the reflector positioned above the fluorescent tubes in the fixture housing. This is a slow, labor intensive process, requiring removal of the light tubes and working overhead standing on a ladder. For commercial installations such as stores, offices, factories, etc., involving hundreds of fixtures, the cost is substantial.

[0003] In U.S. Pat. No. 5,613,761 issued to the present inventors a lightweight reflector using plastic corrugated material with a foil film facing is described. This reflector can be mounted to the tubes themselves, as described in that patent, using cutouts in end pieces of the reflector.

[0004] While that mounting and reflector is a considerable improvement over the prior reflectors, the reflector must first be formed into a trough shape by fixing end pieces to the reflector ends, and installation is still time consuming as the formed reflector must be maneuvered properly to secure the same into place on the tubes.

[0005] In addition, there is a great variety of sizes of tubes and fixtures in use, and it would be advantageous to provide a standardized mounting to fit most or all such light sizes.

[0006] It is the object of the present invention to provide a reflector mounting arrangement and method for fluorescent light fixtures which makes it simple and quick to install a reflector to a variety of light sizes.

[0007] The above object and others which will become apparent upon a reading of the following specification and claims are achieved by a using flat rectangular reflector sheet fitting within the fixture housing, preferably constructed of corrugated plastic with a reflective film on one side which is preformed with a series of pairs of aligned notches on each side edge. A plurality of bracket clips preferably of a generally rounded shape and made from clear plastic sheet stock each have a pair of opposing slots extending into each end of the clip bracket. The slots are spaced and angled to receive a respective reflector side edge when the reflector is formed into an arcuate trough.

[0008] The reflector blank has pairs of aligned slots along its length which may each is received in a clip bracket slot to securely position the reflector on a tube, which is received in a central hole in each bracket clip.

[0009] The bracket clips may come in different sizes and are formed with a knockout hole to receive different sized light tubes. Inwardly extending tabs partially around the hole and are able to be resiliently bent or twisted to allow the tube to be pushed into the hole past the tab, the tab moving back over the tube to prevent the tube from escaping from the hole.

[0013] In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.

[0014] Referring to the drawings, the present invention concerns a fluorescent light fixture 10 (FIG. 1) in which one or more fluorescent light tubes 12 are mounted. According to the present invention, a reflector 14 is mounted to the fixture 10 by an arrangement including a series of clip brackets 16 preferably made of a clear plastic sheet material so as to be as unobtrusive as possible and to not obstruct light emanating from the tube 12.

[0015] Each bracket clips 16 hold the sides edges of the reflector 14 to form the same in a trough shape and are received on the fluorescent tube 12 to hold the reflector over the tube 12 without any connection to the housing 10.

[0016] FIG. 2 shows further details. The reflector 14 is preferably constructed generally as described in U.S. Pat. No. 5,613,761, but other reflectors could be used. A backing of corrugated plastic 18 is slit longitudinally on one side to allow ready forming into a trough shape by bending along the corrugation lines.

[0017] A reflective film 20 is bonded onto the other side to provide maximum reflection of light emanating from the fluorescent tube 12 to concentrate light directed from the tube in the direction towards the open side of the fixture 10.

[0018] Each bracket clip 16 is made from flat plastic sheet stock in a rounded shape having ends 22. A pair of opposing circumferential slots 24 are recessed into the perimeter of each end 22 angled slightly in convergent directions toward each other. The spacing between the two slots 24 is less than the distance between the two side edges 26 of reflector 14 when the reflector lies flat so that the reflector sheet is formed into a trough shape when the side edges 26 are hooked into a respective slot 24 as shown. The reflector 14 has a series of notches 25 cut into its side edges 26. The bracket clips 16 are installed in the notches 25 to locate and secure the same.

[0019] A series of spaced apart bracket clips 16 are installed in this way along the length of the reflector 14 to form a complete trough shape along its length.

[0020] A central hole 28 is sized to receive the light tube 12, the hole 28 extending into a gap 30 provided to create two resiliently bendable tabs 32 extending partially around said hole. Either of the bendable tabs 32 can be twisted aside to allow the light tube 12 to be passed into the hole 28 so that the light tube 12 need not be removed from the fixture 10 to install the reflector 14.

[0021] A knockout 34 is also formed by arcuate slots 36 and scoring 38 to allow use with larger diameter fluorescent light tubes.

[0022] FIGS. 3A–3D show how a single reflector blank 40 can be employed to form various lengths reflectors.

[0023] A series of the notches 25 are provided sufficient in number to allow two, three or four foot reflectors to be constructed while enabling installation of at least two clip brackets.

[0024] A series of imprinted or scored cutting guide lines 42 A, B, C are provided on either end, as well as a center guide line 42D.

[0025] Two longer reflectors 10A for four foot strip fixtures can be produced from the uncut blank 40.

[0026] By cutting along guide lines 42A a shorter reflector 10B is formed for four foot recessed fixtures.

[0027] By cutting along the next guide lines 42B and 42D, a pair of two foot reflectors 10C are provided, each having two aligned pairs of notches 25 for two bracket clips 16.

[0028] By cutting along guide lines 42C, a three foot reflector 10D is created with three bracket clips 16 used to form and support the same.

[0029] Thus, a simple inexpensive arrangement and method for increasing the useful light output of fluorescent fixtures is provided using the reflector and bracket clips as described, which allows quicker and easier retrofitting of light fixtures in the field.