WO2008092899A1 - A downlight box and a method of establishing an electrical installation with such box - Google Patents

A downlight box and a method of establishing an electrical installation with such box Download PDF

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Publication number
WO2008092899A1
WO2008092899A1 PCT/EP2008/051135 EP2008051135W WO2008092899A1 WO 2008092899 A1 WO2008092899 A1 WO 2008092899A1 EP 2008051135 W EP2008051135 W EP 2008051135W WO 2008092899 A1 WO2008092899 A1 WO 2008092899A1
Authority
WO
WIPO (PCT)
Prior art keywords
box
downlight
bottom portion
top portion
vapour barrier
Prior art date
Application number
PCT/EP2008/051135
Other languages
French (fr)
Inventor
Edgar Hanssen
Original Assignee
Optime As
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Optime As filed Critical Optime As
Publication of WO2008092899A1 publication Critical patent/WO2008092899A1/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02—Details
    • H02G3/08—Distribution boxes; Connection or junction boxes
    • H02G3/18—Distribution boxes; Connection or junction boxes providing line outlets
    • H02G3/20—Ceiling roses or other lighting sets

Definitions

  • the invention concerns a downlight box for being arranged in a ceiling structure such that the bottom face of the box is essentially flush with the top face of a ceiling cladding.
  • downlight boxes differ from ordinary boxes for electrical outlets only in that the downlight box has a relatively large height to be able to convey the heat emitted by the lighting fitting away.
  • the vapour barrier which, as will be known, has to be arranged on the warm side of the insulation material, is ruptured in several places in order to enable wiring and cables to be drawn between the outlets or boxes.
  • the box comprises a top portion and a bottom portion that have mutually cooperating coupling means; and that at least one of the sides of the bottom portion has holes or rupture indications for holes for receiving electrical installation pipes or cables, the height of the bottom portion being equal to or larger than the thickness of the electrical installation pipes or cables.
  • the invention also relates to a method of establishing an electrical installation in a ceiling structure comprising roof beams where downlight boxes of the above-described type are used which are connected to each other by means of electrical installation pipes or cables, and wherein the bottom side of the box is essentially flush with the top side of a ceiling cladding.
  • a downlight box which is, in the height dimension, a two piece-box; • That an upper part of the box is arranged such that its bottom edge is essentially flush with the bottom face of the roof beams;
  • That a vapour barrier is arranged on the bottom face of the roof beams
  • the ceiling cladding is arranged adjoining the bottom portion of the box.
  • the box and the working process is also very convenient compared to the operations performed in a building project where different trades are intertwined.
  • the electric fitter or the carpenter himself may arrange the top portion of the downlight box and other ceiling outlets such that the lower edge of the boxes/outlets are flush with the bottom side of the roof beams.
  • the vapour barrier is arranged underneath the roof beams and the boxes/outlets following which battens are mounted a distance down which corresponds, as a minimum, to the height of the lower portion of the box, which is, in turn, at least equal to or larger than the thickness of the used installation cable or pipe material.
  • the electrician may start mounting the lower portions of the boxes and connect pipes and cables between the boxes to each other without there being any risk at all of perforating the vapour barrier.
  • the method is performed in • That a part of the vapour barrier situated below the top portion is cut up such
  • That flaps of the vapour barrier are formed that extend towards each other from each their respective bottom edge of the top portion;
  • the top portion of the box could be provided with a self-adhesive material along the downwardly facing edge.
  • the bottom portion of the downlight box will typically have a height that corresponds to the most used standard dimensions for the battens that are arranged underneath the roof beams. There may either be several heights of bottom portions, or a low bottom portion may be provided that can be interconnected with spacer rings. If the bottom portion consists of several components it is not necessary that they are vapour proof relative to each other, as it is exclusively the tightness between the vapour membrane and the top portion of the box that are decisive.
  • a number of protruding locking pins are provided at the corners of the one box portion, while the other box portion has corresponding holes for receiving and locking said pins in position. Therefore, in practice, the bottom portion will be mounted on the top portion by the bottom portion being shifted vertically upwards to the effect that the pins engage in the holes. By such vertically upwardly travelling movement the membrane can be clamped in place between an upwardly extending flange on the bottom portion of the box and the interior sidewalls of the top portion of the box.
  • Figure 1 shows an embodiment of a downlight box according to the invention
  • Figure 2 shows the top portion of the downlight box shown in figure 1 ;
  • Figure 3 shows the bottom portion of the downlight box shown in figure 2;
  • Figure 4 shows a vertical sectional view through an example of a ceiling structure having a downlight box according to the invention; whereas Figure 5 shows the same as figure 4, but at a later stage in the mounting procedure.
  • the embodiment of the downlight box 1 shown in figure 1 does not differ from an ordinary ceiling outlet apart from its dimensions, however, since a downlight box is larger, in particular in height, due to the box having to be able to distribute the heat from the lighting fitting in the box to the surroundings.
  • the downlight box consists of a top portion 2 and a bottom portion (or more) 3. On one or more sides, the bottom portion 3 is provided with holes or rupture indications 4 to the effect that cables or electrical installation pipes can be drawn inwards through such hole.
  • the height of the bottom portion 3 is larger than or equal to the thickness of the used installation pipe/cable
  • the downlight box is characterised in that it allows the vapour barrier of the ceiling structure to be situated between the top portion 2 and the bottom portion 3, and in such a manner that the vapour barrier can be connected in a vapour-proof manner to the top portion 2.
  • Figure 2 shows the top portion 2 of the downlight box which has, on a pair of opposed sides, side flanges 5 that are preferably used to secure the top portion 2 of the box to a roof beam.
  • holes 6 are provided that are configured for receiving locking pins 7 that can be seen on the bottom portion 3 that is shown in figure 3.
  • the bottom portion 3 is provided with a number of side flanges 8 that have an inclination corresponding to the inclination of the sidewalls of the top portion 2 and that have such dimension that the flanges 8 precisely clamp the vapour barrier tightly between the flanges and the sidewalls on the top portion 2.
  • Figure 4 shows a vertical sectional view through a ceiling structure comprising a roof beam 10 on which a top portion 2 of a downlight box according to the invention is arranged.
  • a vapour barrier 1 1 underneath the roof beams, following which a bottom portion 3 of the box and battens 12 that are to support the ceiling cladding can be mounted.
  • the sequence of how the battens 12 and the lower portions 3 are arranged is not decisive.
  • the vapour barrier is clamped tightly ub or in any other way connected to the top portion 2 of the box in a vapour-proof manner, which, by a preferred embodiment, can be obtained by the membrane being cut up opposite the top portion 2 as is outlined in Figure 4. Then the bottom portion 3 is pressed upwards and in position to the effect that the pins 7 are locked in position in the holes 6 whereby the vapour barrier is clamped between the top portion and the bottom portion.
  • the height of the bottom portion 3 corresponds to the height of the battens 12 to the effect that the bottom face of the bottom portion 3 is substantially flush with the bottom face of battens 12, and such that the bottom face of the mounted downlight box does not protrude further down, but preferably matches in height to the top face of the ceiling cladding as shown by 13 in figure 5.
  • Figure 5 shows that the top portion 2 and the bottom portion 3 are joined; and that the membrane 1 1 is clamped between the sidewalls and flanges, respectively, of these parts.
  • Figure 5 also shows installation pipes 14, 15, where the pipe 15 is shown such that it extends through a batten 12. No matter how the pipes are pulled, there is no risk of the vapour membrane being perforated.
  • a bore is drilled in the ceiling from below by means of a core drill that cuts upwards through the ceiling cladding 13 and the underside of the downlight box, following which a lighting fitting 16 can be arranged. The drilling is easily accomplished by use of a magnet in the downlight box which is known per se.
  • vapour barrier 1 1 can be secured in a vapour- proof manner to the top portion 2 of the downlight box in other ways than described, eg by means of gluing or tape. It will also be understood that the joining means such as the holes and pins 6, 7 described can be configured in many other ways, eg by means of screws.
  • the holes or bores 4 are typically configured in two or more Standard dimensions.

Abstract

A downlight box for being arranged in a ceiling structure (10, 11, 12), preferably for receiving a lighting fitting, wherein the box comprises a top portion (2) that is mounted such that the underside of the top portion is essentially flush with a vapour barrier (11). The bottom portion (3) has a height that corresponds to battens (12) that are configured for supporting the ceiling cladding to the effect that its top face is essentially flush with the bottom side of the bottom portion (3) of the box. The top portion (2) and the bottom portion (3) have mutually cooperating coupling means such that the bottom portion (3) can be mounted on the top portion (2) after the vapour barrier (11) has been laid. The bottom portion (3) has holes or rupture indications for pipes or cables being taken there through to the effect that the electrical installation can be accomplished underneath the vapour barrier (11) without the latter being perforated.

Description

A downlight box and a method of establishing an electrical installation with such box
The invention concerns a downlight box for being arranged in a ceiling structure such that the bottom face of the box is essentially flush with the top face of a ceiling cladding.
It is commonly known to arrange ceiling boxes in the roof structures to the effect that the bottom face of the box is flush with the top face of the finished ceiling cladding. Bores are subsequently drilled in the ceiling cladding for electric outlets, downlights or other to be mounted therein.
In principle, downlight boxes differ from ordinary boxes for electrical outlets only in that the downlight box has a relatively large height to be able to convey the heat emitted by the lighting fitting away. In particular in case of the relatively high downlight boxes, but also in case of the relatively low, ordinary boxes for other electrical installation equipment, it is a problem to have the work done in such a manner and in such sequence that the vapour barrier which, as will be known, has to be arranged on the warm side of the insulation material, is ruptured in several places in order to enable wiring and cables to be drawn between the outlets or boxes. Previously, it was widely used to deploy an electricians' pipe on the cool side of the insulation material, and the known boxes or outlets not being separated from the hot, humid air in the building in a diffusion-proof manner, it will penetrate into the cold pipes and condense. This brings about humidity, resistive fault and short-circuiting and, ultimately, fire.
It is the object of the invention to provide a downlight box that enables such execution of the electrical installation that it is possible to obtain both a relatively large building height of the box and such that the box interior and the associated electrical installations exclusively face towards the warm rooms of the building without an ensuing risk of perforating the vapour membrane.
This object is accomplished in that the box comprises a top portion and a bottom portion that have mutually cooperating coupling means; and that at least one of the sides of the bottom portion has holes or rupture indications for holes for receiving electrical installation pipes or cables, the height of the bottom portion being equal to or larger than the thickness of the electrical installation pipes or cables.
The invention also relates to a method of establishing an electrical installation in a ceiling structure comprising roof beams where downlight boxes of the above-described type are used which are connected to each other by means of electrical installation pipes or cables, and wherein the bottom side of the box is essentially flush with the top side of a ceiling cladding.
The method is characterised in
• That a downlight box is used which is, in the height dimension, a two piece-box; • That an upper part of the box is arranged such that its bottom edge is essentially flush with the bottom face of the roof beams;
• That a vapour barrier is arranged on the bottom face of the roof beams;
• That the bottom portion of the downlight box is mounted on the top portion to the effect that the vapour barrier is clamped between the top portion and the bottom portion of the box; and that
• The ceiling cladding is arranged adjoining the bottom portion of the box. When exercising this method, it will readily be understood which technical improvements are accomplished by using the downlight box according to the invention.
The box and the working process is also very convenient compared to the operations performed in a building project where different trades are intertwined. When the carpenter has deployed the roof beams, the electric fitter or the carpenter himself may arrange the top portion of the downlight box and other ceiling outlets such that the lower edge of the boxes/outlets are flush with the bottom side of the roof beams. Then the vapour barrier is arranged underneath the roof beams and the boxes/outlets following which battens are mounted a distance down which corresponds, as a minimum, to the height of the lower portion of the box, which is, in turn, at least equal to or larger than the thickness of the used installation cable or pipe material. Then the electrician may start mounting the lower portions of the boxes and connect pipes and cables between the boxes to each other without there being any risk at all of perforating the vapour barrier.
According to a preferred embodiment the method is performed in • That a part of the vapour barrier situated below the top portion is cut up such
• That flaps of the vapour barrier are formed that extend towards each other from each their respective bottom edge of the top portion; and
• That the flaps are pressed upwards for abutment on the interior sidewalls of the top portion by means of upwardly extending flanges on the bottom portion, when the latter is mounted up below the top portion.
This is a very simple way of ensuring that the interiors of the downlight boxes sealingly join the vapour barrier. Alternatively the top portion of the box could be provided with a self-adhesive material along the downwardly facing edge. The bottom portion of the downlight box will typically have a height that corresponds to the most used standard dimensions for the battens that are arranged underneath the roof beams. There may either be several heights of bottom portions, or a low bottom portion may be provided that can be interconnected with spacer rings. If the bottom portion consists of several components it is not necessary that they are vapour proof relative to each other, as it is exclusively the tightness between the vapour membrane and the top portion of the box that are decisive.
By a preferred embodiment, a number of protruding locking pins are provided at the corners of the one box portion, while the other box portion has corresponding holes for receiving and locking said pins in position. Therefore, in practice, the bottom portion will be mounted on the top portion by the bottom portion being shifted vertically upwards to the effect that the pins engage in the holes. By such vertically upwardly travelling movement the membrane can be clamped in place between an upwardly extending flange on the bottom portion of the box and the interior sidewalls of the top portion of the box.
The invention will now be explained in further detail by the following description of an embodiment, reference being made to the drawing, wherein:
Figure 1 shows an embodiment of a downlight box according to the invention;
Figure 2 shows the top portion of the downlight box shown in figure 1 ;
Figure 3 shows the bottom portion of the downlight box shown in figure 2;
Figure 4 shows a vertical sectional view through an example of a ceiling structure having a downlight box according to the invention; whereas Figure 5 shows the same as figure 4, but at a later stage in the mounting procedure.
In principle, the embodiment of the downlight box 1 shown in figure 1 does not differ from an ordinary ceiling outlet apart from its dimensions, however, since a downlight box is larger, in particular in height, due to the box having to be able to distribute the heat from the lighting fitting in the box to the surroundings. According to the invention, the downlight box consists of a top portion 2 and a bottom portion (or more) 3. On one or more sides, the bottom portion 3 is provided with holes or rupture indications 4 to the effect that cables or electrical installation pipes can be drawn inwards through such hole. According to the invention, the height of the bottom portion 3 is larger than or equal to the thickness of the used installation pipe/cable, and the downlight box is characterised in that it allows the vapour barrier of the ceiling structure to be situated between the top portion 2 and the bottom portion 3, and in such a manner that the vapour barrier can be connected in a vapour-proof manner to the top portion 2. As will be explained later in the context of figures 4 and 5, it is thereby possible to establish an electric installation completely underneath the vapour barrier and without an ensuing risk of the latter being perforated.
Figure 2 shows the top portion 2 of the downlight box which has, on a pair of opposed sides, side flanges 5 that are preferably used to secure the top portion 2 of the box to a roof beam. At the corners of the top portion 2, holes 6 are provided that are configured for receiving locking pins 7 that can be seen on the bottom portion 3 that is shown in figure 3. Moreover, the bottom portion 3 is provided with a number of side flanges 8 that have an inclination corresponding to the inclination of the sidewalls of the top portion 2 and that have such dimension that the flanges 8 precisely clamp the vapour barrier tightly between the flanges and the sidewalls on the top portion 2. Figure 4 shows a vertical sectional view through a ceiling structure comprising a roof beam 10 on which a top portion 2 of a downlight box according to the invention is arranged. As soon as the downlight box is arranged, it is possible to mount a vapour barrier 1 1 underneath the roof beams, following which a bottom portion 3 of the box and battens 12 that are to support the ceiling cladding can be mounted. The sequence of how the battens 12 and the lower portions 3 are arranged is not decisive. On the other hand it is decisive that the vapour barrier is clamped tightly ub or in any other way connected to the top portion 2 of the box in a vapour-proof manner, which, by a preferred embodiment, can be obtained by the membrane being cut up opposite the top portion 2 as is outlined in Figure 4. Then the bottom portion 3 is pressed upwards and in position to the effect that the pins 7 are locked in position in the holes 6 whereby the vapour barrier is clamped between the top portion and the bottom portion.
Of course, it is decisive that the height of the bottom portion 3 corresponds to the height of the battens 12 to the effect that the bottom face of the bottom portion 3 is substantially flush with the bottom face of battens 12, and such that the bottom face of the mounted downlight box does not protrude further down, but preferably matches in height to the top face of the ceiling cladding as shown by 13 in figure 5.
Figure 5 shows that the top portion 2 and the bottom portion 3 are joined; and that the membrane 1 1 is clamped between the sidewalls and flanges, respectively, of these parts. Figure 5 also shows installation pipes 14, 15, where the pipe 15 is shown such that it extends through a batten 12. No matter how the pipes are pulled, there is no risk of the vapour membrane being perforated. When the ceiling is finished and painted, a bore is drilled in the ceiling from below by means of a core drill that cuts upwards through the ceiling cladding 13 and the underside of the downlight box, following which a lighting fitting 16 can be arranged. The drilling is easily accomplished by use of a magnet in the downlight box which is known per se.
It will be understood that the vapour barrier 1 1 can be secured in a vapour- proof manner to the top portion 2 of the downlight box in other ways than described, eg by means of gluing or tape. It will also be understood that the joining means such as the holes and pins 6, 7 described can be configured in many other ways, eg by means of screws. The holes or bores 4 are typically configured in two or more Standard dimensions.

Claims

C l a i m s
1. A downlight box for being arranged in a ceiling structure such that the bottom face of the box is essentially flush with the top face of a ceiling cladding, characterised in that the box comprises a top portion and a bottom portion that have mutually cooperating coupling means on a respective edge which is essentially in parallel with said bottom face; and that at least one of the sides of the bottom portion has holes or rupture indications for holes for receiving electrical installation pipes or cables, the height of the bottom portion being equal to or larger than the thickness of the electrical installation pipes or cables.
2. A downlight box according to claim 1 , characterised in that several bottom portions are provided that have mutually different heights.
3. A downlight box according to claims 1 or 2, characterised in that a bottom portion is composed of several portions in height by means of associated coupling means.
4. A downlight box according to claims 1 -3, characterised in that said coupling means comprise holes and corresponding locking pins in the cooperating box portions.
5. A downlight box according to claims 1 -4, characterised in that at least two cooperating box portions have sidewalls that extend a distance into the neighbouring portion for abutment on the interior sidewall thereof.
6. A method of establishing an electrical installation in a ceiling structure comprising roof beams where downlight boxes are used which are connected to each other by means of electrical installation pipes or cables, and wherein the bottom side of the box is essentially flush with the top side of a ceiling cladding, characterised in
• That a downlight box is used which is, in the height dimension, a two piece-box; • That an upper part of the box is arranged such that its bottom edge is essentially flush with the bottom face of the roof beams;
• That a vapour barrier is arranged on the bottom face of the roof beams;
• That the bottom portion of the downlight box is mounted on the top portion to the effect that the vapour barrier is clamped between the top portion and the bottom portion of the box; and that
• The ceiling cladding is arranged adjoining the bottom portion of the box.
7. A method according to claim 6, characterised in
• That a part of the vapour barrier situated below the top portion is cut up such
• That flaps of the vapour barrier are formed that extend towards each other from each their respective bottom edge of the top portion; and • That the flaps are pressed upwards for abutment on the interior sidewalls of the top portion by means of upwardly extending flanges on the bottom portion, when the latter is mounted up below the top portion.
PCT/EP2008/051135 2007-01-31 2008-01-30 A downlight box and a method of establishing an electrical installation with such box WO2008092899A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DKPA200700156 2007-01-31
DK200700156A DK176703B1 (en) 2007-01-31 2007-01-31 Downlight box and method for establishing an electrical installation with such a box

Publications (1)

Publication Number Publication Date
WO2008092899A1 true WO2008092899A1 (en) 2008-08-07

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ID=39316435

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2008/051135 WO2008092899A1 (en) 2007-01-31 2008-01-30 A downlight box and a method of establishing an electrical installation with such box

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WO (1) WO2008092899A1 (en)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2150650A (en) * 1983-11-14 1985-07-03 Timber Res Dev Ass Sealing shroud
US4927039A (en) * 1989-07-12 1990-05-22 Viscount Industries Limited Electrical box
US4952754A (en) * 1988-08-23 1990-08-28 Glen Rye Vapor seal outlet box
DE4324058A1 (en) * 1993-07-17 1995-01-19 Kaiser Gmbh & Co Kg Hollow body for electrical installation
EP1132682A2 (en) * 2000-03-11 2001-09-12 Kaiser GmbH & Co. Hollow article for an electrical installation
US20030116341A1 (en) * 2000-11-29 2003-06-26 Gilleran William J. Exterior electrical box waterproofing system

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2150650A (en) * 1983-11-14 1985-07-03 Timber Res Dev Ass Sealing shroud
US4952754A (en) * 1988-08-23 1990-08-28 Glen Rye Vapor seal outlet box
US4927039A (en) * 1989-07-12 1990-05-22 Viscount Industries Limited Electrical box
DE4324058A1 (en) * 1993-07-17 1995-01-19 Kaiser Gmbh & Co Kg Hollow body for electrical installation
EP1132682A2 (en) * 2000-03-11 2001-09-12 Kaiser GmbH & Co. Hollow article for an electrical installation
US20030116341A1 (en) * 2000-11-29 2003-06-26 Gilleran William J. Exterior electrical box waterproofing system

Also Published As

Publication number Publication date
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