CA2254236A1 - Hanger bar assembly - Google Patents
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- CA2254236A1 CA2254236A1 CA 2254236 CA2254236A CA2254236A1 CA 2254236 A1 CA2254236 A1 CA 2254236A1 CA 2254236 CA2254236 CA 2254236 CA 2254236 A CA2254236 A CA 2254236A CA 2254236 A1 CA2254236 A1 CA 2254236A1
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Abstract
A hanger bar assembly for supporting an outlet box between spaced apart support elements including a support bar including a first and second telescopically extendable elongate channel members. Each channel member has an upper wall and afirst and second space side walls extending therefrom and defining a channel interior.
At least one of the side walls of each of the first and second channel members has an inwardly turned flange. The first and second channel members are longitudinally alignable such that the flange of the first channel member is engageable along atransverse extent of the second channel member upper wall. The flange of the second channel member is engageable along a transverse extent of the first channel member upper wall. A clamping device for urging the flanges into force engagement with the transverse extent of a corresponding channel member is also provided, thereby restricting movement between the first and second channel members. Additionally, a securement device is provided for securing the support bar to the spaced supportelements.
At least one of the side walls of each of the first and second channel members has an inwardly turned flange. The first and second channel members are longitudinally alignable such that the flange of the first channel member is engageable along atransverse extent of the second channel member upper wall. The flange of the second channel member is engageable along a transverse extent of the first channel member upper wall. A clamping device for urging the flanges into force engagement with the transverse extent of a corresponding channel member is also provided, thereby restricting movement between the first and second channel members. Additionally, a securement device is provided for securing the support bar to the spaced supportelements.
Description
CA 022~4236 1998-11-18 577-112 (T&B 1252) HANGER BAR ASSEMBLY
FIELD OF INVENTION:
The present invention relates generally to a hanger bar assembly for supporting electrical fixtures. More particularly, the present invention relates to a hanger bar assembly having telescopically engaged channel members having uniform cross-sectional profiles and that are engagable with each to restrict the relative motion of the channel members upon securement of an electrical outlet box to the channel members.
BACKGROUND OF THE INVENTION:
In order to secure electrical fixtures such as lights and fans in ceilings, a hanger bar device is typically employed. It is very important that a fixture be adequately supported in the ceiling since improper support could lead to the fixture breaking away from the ceiling. Ceilings are typically constructed of structural members including a series of spaced joists which are covered by lathe and plaster or a gypsum wallboard often referred to as drywall. The ceiling covering material or sheathing is not designed to support loads perpendicular to its surfaces. Therefore, in order to suspend electrical fixtures from a ceiling, the fixture's weight must be supported by the joists. To achieve this, a fixture may be secured directly to a joist, however, this limits the range of locations where the fixture may be placed. Such a limitation is problematic since it is often desirable to place the fixture in a specific position on the ceiling. Therefore, if no joist is adjacently positioned to the desired location, direct joist connection is not possible. A preferred solution for supporting electrical fixtures in the ceiling is the use of a hanger bar assembly. The hanger bar allows for the joists to be used for supporting an electrical fixture while still providing flexibility in positioning.
Hanger bar assemblies are typically extensible telescopic members that are disposed in between the ceiling joists and are securable thereto. An assembly's length, therefore, is adjustable to accommodate various joist spacing distances. Electrical outlet boxes, junction boxes and the like are then secured to the transverse members of CA 022~4236 1998-11-18 the assembly. Such electrical boxes provide a termination point for electrical wiring as well as an attachment point for the electrical fixture. Typically the outlet box can be positioned at various points along the length of the members in order to properly position the fixture attached thereto. In conventional construction a cut out is made in the ceiling covering material in order to provide clearance for the electrical outlet box, thereby allowing the fixture to be secured to the outlet box.
The outlet box once secured to the hanger bar assembly is typically used to support the electrical fixture. The National Electric Code sets a maximum weight that an outlet box may support. Outlet boxes may either support lighting fixtures weighing up to 50 Ibs. or ceiling fans weighing up to 35 lbs. Fixtures exceeding these weight limits must be supported independently of the box such as directly to the joists or other structural member.
Hanger bar assemblies can be divided into two general categories, standard and heavy duty and are distinguishable by the amount of weight they can safely support.
Standard hanger bars are typically used to support lightweight lighting fixtures which are generally less than five pounds.
An adjustable support for use with old work applications is described in U.S.
Patent 2,670,919 to Esoldi. The support includes a pair of interlocking channel members having uniforrr. U-shaped profiles. The channels are aligned such that the base portion of the channels form the top and bottom of the support. The bases include spaced slots which permit a prying tool to be inserted therein to adjust the length of the support. The channels require a pair of relatively narrow end straps to hold them and which permit longitudinal movement of the channel members relative to each other but prevent independent lateral movement of the members. The channelsare only secured together by the straps, thereby resulting in only limited resistance to static and dymanic loadings. A supporting strap is slidably disposed between the two~
end straps and is capable of supporting an outlet box. Such that upon the tightening of -T ~
CA 022~4236 1998-11-18 the box to the strap the channel members are clamped together. The supporting strap however, only engages a relatively small section of channel.
In addition, the only two relatively thin edges of the channels are brought intoengagement when the support strap is tightened. Therefore, such a design would be susceptible to slippage between the channels under the cyclic vibrational loads of a fixture such as a ceiling fan. Accordingly, this device is typically used to support relatively lightweight fixtures. In addition, since triangular spikes are used on each end of the support to engage the ceiling studs, an the force required to drive the projections increases as the width of the triangular projection increases. Therefore, it would be very difficult for an installer to be certain from feel alone that the projections where inserted a proper distance into the joists. If such a device were used in an old work application it would be difficult to visually determine if proper engagement had occurred.
U.S. Patent No. 2,925,236 to Cook et al. discloses a standard duty hanger bar assembly. The assembly includes telescopically engagable slotted channel memberspositionable between two ceiling joists. A box carrier is inserted in the channel members and has guide prongs extending from the slots. An outlet box is insertable over the prongs and is secured to the assembly by a box fastener which is securable to the box carrier by a threaded bolt. Upon the tightening of the bolt, a portion of the outlet box and a portion of the channel members are clamped together between thebox carrier and fastener, thereby securing the box to the assembly. The box carrier, however, only engages a small amount of channel section thereby providing a relatively small clamping area.
Heavy duty hanger bars are typically employed for supporting heavy lighting fixtures up to 50 Ibs. and ceiling fans weighing 35 lbs. Ceiling fans require high load bearing supports not only due to their weight but also due to the torque and vibrational forces that are generate by the rotation of the motor and fan blades. Relatively small weight differences between the blades of a ceiling fan can produce rotational ,, CA 022~4236 1998-11-18 imbalances leading to large vibrational forces. Therefore, a heavy duty hanger bar is required when suspending electrical fixtures such as ceiling fans.
Heavy duty hanger bars assemblies must be able to maintain their rigidity and length under high load situations. A load acting perpendicular to the length of the telescopic members tends to deflect the assembly toward the direction of the load. The degree of deflection increases when the members are free to move relative to each other as the members tend to be pulled apart by the load. Under certain circumstances, the deflection could be to such a degree that the members could be pulled completely apart resulting in the rt?lease of the outlet box and fixture attached thereto. Therefore, it is important that once the assembly is installed the members be secured so that they resist motion between themselves.
Heavy duty hanger bars may be designed for installation in new work or old work applications. New work applications include installations where the ceilingcovering material has not yet been installed and access to the joists is available. This may occur in situations such as new construction or renovations where the ceiling material has been removed. Old work applications include installations where theceiling covering material is already installed and the hanger bar needs to be inserted into an outlet box clearance opening cut into the ceiling. In such applications access to the joists is typically extremely limited. This situation is typically found when a ceiling fan is to be installed in a location where a ceiling lighting fixture had previously been installed.
Hanger bar assemblies capable of supporting loads such as ceiling fans and adapted for use in old work applications have been disclosed in U. S. Patent Nos.
5,150,868 to Keaden; 5,044,582 to Walters; and 4,463,923 to Reiker.
Reiker discloses a heavy duty junction box hanger assembly including a brace having two elongated members that are threadedly coupled such that relative rotation of one member with respect to the other causes the hanger assembly to expand or CA 022~4236 1998-11-18 contract. Thus, the length of the assembly is maintained by the engagement of the threaded coupling. The ends of the brace include spikes which engage the joist when the members are expanded. In order to install the assembly, expansion of the brace requires an installer to manually turn one of the members until the brace engages the S joists. This is a time-consuming task especially in situations having a large distance between the joist In addition, Reiker discloses a multi-component apparatus for securing the outlet box to the brace. First a two-part bracket must be secured to the brace and then the outlet box must be secured to the bracket assembly. This mounting method is time consuming and expensive to manufacture due to the various components involved.
The device disclosed in Keaden is similar to Reiker in that two members are threadedly engaged and expandable by rotation of one member with respect to the other. Hereto the length of the assembly is provided by the engagement of the threaded coupling. Keaden, however, addresses one of the problems associated with Reiker by employing a quick release mechanism that allows the members to extend freely without the need for rotation. The quick release mechanism releases the members from the normal threaded interconnection. Once released, the members canbe expanded relatively quickly. In order to achieve this quick release capability, however, the device requires the use of a special nut assembly having various segments and a spring. The nut is designed to either clamp down for threaded engagement or expand for quick release position depending on which direction the members are moved. The Keaden design, therefore, is fairly complex requiring several components in order to achieve its benefits.
In addition to the various components required to achieve the quick release function, the Keaden design also requires the use of a separate piece in order to attach the outlet box to the transverse brace. Keaden discloses the use of a U-shaped saddle bracket that rests on top of the brace and is securable to an outlet box by way of fastening hardware.
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CA 022~4236 1998-11-18 Walters discloses slidably telescopically eilgageable tubes. The bottom walls ofthe tubes have apertures therein. The apertures permit a prying tool to be inserted therein in order to expand the tubes, thereby forcing teeth disposed at both ends of the brace into the joists. In order to prevent the members from shifting under the load of the fixture, a spring bias roller is employed. The roller bears down on the upper surface of the inner tube thereby creating constant lateral pressure. The force of the roller, however, acts over only a relatively small area. Additionally, the spring force is susceptible to weakening over time. Both of these factors create the possibility that slippage might occur allowing the tubes to shift, thereby releasing the teeth from the joist. In such a situation the only support would be provided by flanges which would be resting on and supported entirely by the ceiling. As previously stated, ceilings are not typically designed to support such loads, and therefore, the fixture could possibly fall from the ceiling.
In addition, the Walters design requires the use of a knurled tension wheel, a spring and a housing which supports the assembly in order to restrict the relative motion of the members. Furthermore, Walters discloses a separate component for supporting an outlet box to the tubes comprising a bracket which is adapted to straddle over the upper end of the outer tube and which is connected to a second bracket which is adapted to ride on the bottom portion of the outer tube. Mounting bolts extend through both brackets into an outlet box which is secured in a conventional manner by nuts and bolts. These extra components increase the manufacturing costs of the assembly.
Accordingly, it would be desirable to devise a hanger bar assembly capable of supporting heavy loads such as ceiling fans that can be quickly installed and relatively simple to produce as well as being sufficiently rigid to resist vibrational forces under the heavy load of a fixture.
I
CA 022~4236 1998-11-18 SUMMARY OF THE INVENTION:
It is an object of the present invention to provide a hanger bar assembly for rigidly supporting an outlet box between spaced apart support elements.
It is a further object of the present invention to provide a hanger bar assemblyincluding a pair of interlocking telescopically engageable channel members which may be adjusted to an operating length and clamped to prevent relative channel member motion.
It is yet a further object of the present invention to provide a hanger bar assembly including having spacers slidably engageable along the length of the channel members for properly spacing the hanger bar assembly in the ceiling.
It is still a further object of the present invention to provide a hanger bar assembly including a joist engaging device which provides an installer with positive notice of proper engagement.
In the efficient attainment of these and other objects the present invention provides a hanger bar assembly for supporting an outlet box between spaced apartsupport elements including a support bar including a first and second telescopically extendable elongate channel members. Each channel member has an upper wall and afirst and second space side walls extending therefrom and defining a channel interior.
At least one of the side walls of each of the first and second channel members has an inwardly turned flange. The first and second channel members are longitudinally alignable such that the flange of the first channel member is engageable along atransverse extent of the second channel member upper wall. The flange of the second channel member is engageable along a transverse extent of the first channel member upper wall. A clamping device for urging the flanges into force engagement with the transverse extent of a corresponding channel member is also provided, thereby _ .
CA 022~4236 1998-11-18 restricting movement between the first and second channel members. Additionally, a securement device is provided for securing the support bar to the spaced supportelements.
In a preferred embodiment the hanger bar assembly joist engaging devise includes at least one spike member extending from opposing ends of the hanger bar assembly. The spikes have an elongate portion having a substantially uniform cross-section which terminates in a tapered endpoint. In addition, a pair of spacers for properly positioning the hanger bar assembly with respect to the support elements is preferable provided. The spacers are slidably attachable to opposed ends of the support bar, and each spacer is positionably adjustable along a length ofthe channel member to which the spacer is attached.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure I is a perspective view of the hanger bar assembly of the present invention.
Figure 2 is a cross-sectional view of the hanger bar assembly of the present invention with an outlet box secured thereto.
Figure 3 is a cross-sectional view of the assembly taken along line III-III of Figure 1.
Figure 4 top planar view of the hanger bar assembly.
Figure 5 is a elevational end view of one of the channel members.
Figure 6 is a detail cross-sectional view of an embodiment of the gripping element of the present invention taken along line VI-VI of Figure 5.
Figure 7 is a detail cross-sectional view of a preferred embodiment of the gripping element of the present invention.
Figure 8 is a perspective view of a preferred embodiment of a prying tool of thepresent invention.
Figure 9A is a perspective view of a channel member and extension member of the present invention.
CA 022~4236 1998-11-18 Figure 9B is an elevational end view of the extension member and connector of the present invention.
Figure 10 is a cross-sectional view ofthe interlocked channel members with the connector attached thereto taken along line X-X of Figure 1.
Figure 11 is an elevational front view of a spacer of the present invention.
Figure 12 is an elevational end view of a channel member having a spacer of Figure 11 attached thereto.
Figure 13 is an elevational side view of the hanger bar assembly of Figure 1.
Figure 14 is an elevational side view of the hanger bar assembly of Figure 1 in combination with an I-beam support member.
DETA~LED DESCRIPTION OF THE PREFERRED EMBODIl~'fENT
The hanger bar assembly of the present invention is adapted to support relatively heavy electrical fixtures such as ceiling fans in "old work" applications.
Ceiling fans, in addition to being relatively heavy, typically create cyclic loadings and vibrational forces due to the rotation of the motor and fan blades. Such forces must be adequately supported in order to ensure the fixture does not separate from the ceiling support structures to which it is attached. The hanger bar assembly of the present invention provides support for such fixtures as ceiling fans by maintaining its rigidity in configuration even under relatively high loadings.
Referring to Figure 1, the hanger bar assembly 10 formed in accordance with the preferred embodiment of the present invention is shown. Hanger bar assembly 10 includes a pair of channel members 20, 22, stud engaging members 60 and spacers 70.
Assembly 10 is adapted to be employed in "old work" applications where the ceiling covering material such as drywall or plaster has already been attached to the ceiling joists. However, it is conceivable that assembly 10 could also be used in "new work"
applications in which the joists are exposed and accessible.
Hanger bar assembly 10 is positionable between spaced apart ceiling joists (not shown) and securely engageable therewith. As shown in Figure 2, an outlet box, CA 022~4236 1998-11-18 junction box or the like 100 may be secured to the hanger bar assembly 10 by a U-bolt and nut combination 102, 104, in a manner which will be described in detail below.
Once the box is secured, an electrical fixture (not shown), such as a ceiling fan, may then be secure to the outlet box in a manner well known in the art. The hanger bar S assembly 10 and the joists provide the necessary support for the fixture.
Referring additionally into Figures 3 and 4, channel members 20, 22 are telescopically engageable elongate members which form a support apparatus. Each channel member 20, 22 is freely slidable with respect to the other, thereby permitting the length of hanger bar assembly 10 to be easily adjusted. In old work applications, hanger bar assembly 10 is preferably inserted up in the ceiling i.e., above the wallboard or plaster sheathing, through a cut out opening in the sheathing which is similar in sized to the perimeter of the outlet box being installed. This creates a relatively small space through which hanger bar assembly 10 must pass. Accordingly, assembly 10 is preferably collapsed to approximately its shortest length, as shown in Figure 4, upon insertion into the ceiling in order to facilitate installation. Once inside the ceiling, channel members 20, 22 may be quickly and easily expanded to an initial extension length substantially equivalent to the distance between the ceiling joists. Final expansion of channel members 20, 22 to an operating length results in joists eng~ging members 60 being secured to the joists.
As shown in Figures 2 and 3, channel members 20, 22 are preferably similarly formed interlocking members having substantially identical cross-sectional profiles.
Accordingly, the manufacturing of the hanger bar assembly is simplified and improved efficiency is obtained since only one part need be produced and cut into fini~hing lengths to form the two channel members.
Each channel member 20, 22 has a generally square-shaped cross-section including an upper wall 23 and a first and second space side walls 24, 25 extendin&
downwardly therefrom. Both side walls 24, 25 have inturned flanges 26 having spaced offset ends 30. Ends 30 define a slot 32 which extends the length of the channel CA 022~4236 1998-11-18 member. Side walls 24, 25 are joined to upper wall 23 and flan~es 26 by rounded corners 27. Channel members 20, 22 may be interlocked with each other by aligning the channel members end to end with one channel inverted with respect to the other and moving the channel members together such that a portion of each channel slides within the other. Channel members 20, 22 are so configured such that when they are interlocked a significant portion of each channel engages the other channel. As shown in Figure 3, flanges 26 of each channel member 20, 22 abut a transverse extent of the corresponding channel member over the length of assembly lO in which the channelmembers interlock.
When an electrical fixture is secured to hanger bar assembly lO, the resultant load acting downwardly thereon tends to bow the assembly pulling the channel members apart. If the channel members, once installed, were permitted to move relative to each other, this tendency to bow would not be restricted, and the resultant sagging, would present an opportunity for the channel members to slip apart and release the outlet box. If this were to occur, the fixture could come loose from the ceiling leading to a potentially hazardous situation due to the weight of the fixture.
However, by restricting relative movement between the channel members, the rigidity of the hanger bar assembly is increased, and its tendency to bow downwardly is greatly reduced. Additionally, in ceiling fan applications, the hanger bar assembly experiences torques and vibrational forces as well as static vertical loadings. A hanger barassembly's resistance to these dynamic forces is also augmented when the rigidity of the assembly is increased. In the present invention, the requisite rigidity is obtained by preventing relative movement between channel members 20, 22 by way of the forcedengagement of flanges 26 with the channel member upper walls 23 as described in detail below.
In the preferred embodiment, opposed flanges 26 and channel upper wall 23 are urged into forced engagement when outlet box lO0 is secured to hanger bar assembly lO. As shown in Figure 2, outlet box lO0 is secured to hanger bar assembly lO by U-bolt 102 which is placed over hanger bar assembly lO such that it straddles I
CA 022~4236 1998-11-18 channel members 20, 22. U-bolt 102 is sized such that it extends through apertures 106 formed in the back wall of outlet box lO0. Such apertures 106 are typically formed in standard outlet boxes in accordance with industry practice and standards. Nutfasteners 104 secure outlet box 100 to hanger bar assembly 10 and also provide the clamping force which urges flanges 26 and channel member upper walls 23 together, thereby restricting longitudinal movement between channel members 20, 22.
In the plere--ed embodiment, this forced engagement occurs adjacent the four corners 27 of channel members 20, 22. Flanges 26 of each channel member 20, 22 engage the other channel member over a transverse extent of an adjacently opposed portion of upper wall 23. As a result of the transverse and longitudinal dimensions of flanges 26, a substantial area of interference is created between channel members 20, 22. The clamping force generated upon securement of outlet box 100, therefore, acts over a significant area providing hanger bar assembiy lO with the ability to resist slippage between channel members 20, 22 even under the high loads and vibrationsgenerated by fixtures such as ceiling fans.
In order to increase the effectiveness of the clamping force, at least one of the channel members 20, 22 may preferably include a gripping element 40 formed alongthe length of the channel on the surfaces where the channels overlap and are brought into forced engagement upon securement of outlet box 100. These surfaces, shown in Figure 5, include the inside surface of flange 26 attached to side wall 24, the outer surface of the flange 26 attached to side wall 25, the inside corner formed by the junction of upper wall 23 and side wall 24, and an exterior portion of upper wall 23 adjacent side wall 25. The gripping element 40 may include a plurality of longitudinally spaced groves 42 as shown in Figure 6. Grooves 42 form an irregular non-smooth surface which increases the frictional coefficient of the engagement surfaces. This maximizes the resistance to slippage between channels for a givenclamping force. In an alternative embodiment, both channels 20, 22 may include agripping element 40 along their lengths.
CA 022~4236 1998-11-18 In a preferred embodiment shown in Figure 7~ gripping element 40' may include a plurality of spaced ridge-like projections 44, formed on channel surfaces brought into forced engagement described above. Projections 44 are preferably knurls and may be formed in a manner well known in the art. In an alternative preferred embodiment, knurls may be formed on the engagement surfaces of both channel members 20, 22.
In order to increase the rigidity of channel members 20, 22, side wall 25 of each channel member preferably includes a generally M-shaped cross-sectional profile.
As shown in cross-section in Figure 5, side wall 25 has a somewhat indented central planar portion 108 ending in raised U-shaped structures 110. Such a configuration increases the ability of side wall 25 to resist vertical loadings and moments thereby increasing hanger bar assembly's 10 overall ability to resist such forces.
When channel members 20, 22 are interlocked, both vertical and transverse movement between the channel members is restricted. Vertical movement is prevented by the general engagement between backwalls 23 and flanges 26 of channel members20, 22. Transverse movement is prevented by the cooperation between flanges 26 and a longitudinally extending track 46 formed in upper walls 23 of each of channel members 20, 22. As shown in Figure 3, tracks 46 are formed by an offset portion of upper wall 23. Each track has a substantially planar bottom run 48 sized to receive a flange 26 from a corresponding channel member. Track 46 is bounded by side walls49a, 49b formed by a lower portion of sidewall 24 and a diagonally extending transition portion which extends outwardly and upwardly from track run 48, respectively. Accordingly, when outlet box 100 is clamped to hanger bar assembly 10, channel members 20, 22 are longitudinally, transversely and vertically locked such that the rigidity of hanger bar assembly 10 is greatly enhanced. Furthermore, by incorporating the transverse interlocking device, i.e., track and flange, into the profile of the channel members no additional components are required, thereby reducing m~nuf~cturing and assembly costs.
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CA 022~4236 1998-11-18 In addition to providing a rigid support structure, the manner of interlocking of the two channel members 20, 22 permits the channels to be expanded by an installer using only one hand. This is especially significant in old work applications where once hanger bar assembly 10 is placed in the ceiling access thereto is limited. When S channels 20, 22 are interlocked one side wall of the hanger bar assembly is formed by one portion of a channel member with the other hanger bar assembly side wall being formed by a portion of the other channel member. Therefore, when the installer wraps a hand around channel members 20, 22, the installer can move one channel in one direction with their thumb and the other channel in the opposite direction with the other fingers, thereby expanding hanger assembly 10. In this manner, an installer may manually expand assembly 10 to a length such that the joist engaging membf~rs 60 abut the joists. Further expansion of assembly 10 to its operating length, resulting in its proper securement to the joists, is provided by further expansion of hanger bar assembly 10 by way of slots 34 and a prying tool.
With reference to Figures 3 and 4, channel members 20, 22 preferably include a plurality of longitudinally spaced elongate slots 34 formed through upper wall 23. Slots 34 provide a means for telescopically expanding hanger bar assembly 10 to an operating length such that joist engaging members 60 are secured in the joists. When channel members 20, 22 are interlocked one channel member is inverted with respect to the other thereby placing slots 34 of each member in spaced vertical alignment. As shown in Figure 3, upper wall 23 of one channel member substantially forms a top wall 36 of hanger bar assembly 10 and upper wall 23 of the other channel member substantially forms an assembly bottom wall 38. Slots 34 are sized to receive a prying tool which may be used to urge channel members 20, 22 apart thereby expanding the length of hanger bar assembly 10. Channel members 20, 22 may then be expended byvertically inserting the prying tool through a pair of aligned slots 34 in each channel member and rotating the tool about a horizontal axis perpendicular to the length of Xanger bar assembly 10. Expansion of hanger bar assembly 10 to the operating length forces joist eng~gin~ members 60 into the joists thereby securing hanger bar assembly 10 thereto. Slots 34 may further include rounded end portions 35 which will cradle a CA 022~4236 1998-11-18 prying tool 90 inserted in slots 34 in order to keep the prying tool in proper alignment to the axial line of action required to extend hanger bar assembly 10. In the preferred embodiment shown in Figure 8, prying tool 90, which may be provided with hanger bar assembly 10, may consist of a rod having a diameter slightly less than the radius of the slots rounded end portion 35. Alternatively, a similarly sized screw driver or other rigid elongate device may be employed to provide the prying function.
Referring to Figures 1 and 4, joist engaging members 60 are disposed at the distal ends of each channel member 20, 22 and extend from opposite sides of hanger bar assembly 10. Joist engaging members 60 are preferably rigidly secured to upper wall 23 and to flanges 26 of each channel member 20,22. Each joist engaging member 60 includes a pair of laterally spaced spikes 62 extending longitudinally outwardly from channel member to which it is attached. Spikes 62 are separated by a web 63 which is preferably welded to the corresponding channel member. Spikes 62 are adapted to be driven into the joists upon the outward expansion of channel members 20, 22 thereby fixedly securing hanger bar assembly 10 at both ends.
Each spike 62 preferably includes an elongate portion 64 having a uniform cross-section which terminates in a tapered end point 66. Such a configuration permits an installer of a hanger bar assembly to easily ascertain when spikes 62 are fully inserted within the joist. Upon the expansion of channel members 20, 22, spike end points 66 first engage the joists. Once the relatively short taper end points 66 enter the joists, the force exerted on prying tool 90 required to drive the remainder of spikes 62 further into the joist is substantially constant due to the uniform cross-section of elongate portion 64. When spikes 62 are fully inserted, the distal end of the channel members will butt the joist at which point the installer can easily sense that spikes 62 are fully engaged.
In contrast, joist engaging devices of the prior art typically include a triangular shape member having a varying cross-section throughout its length. Therefore, the force required to urge joist engaging member increases throughout the length of the CA 022~4236 1998-11-18 member. Accordingly, an installer would be uncertain if the joist engaging device has been fully engaged and the support member is butting the joist or if still more force is needed to drive in the device.
The manner in which outlet box lO0 is secured to hanger bar assembly 10 permits outlet box 100 to be located on any position along the length of assembly 10.
However, in order to achieve the clamping function, the box must be secured to assembly 10 at a point where channel members 20, 22 overlap and are interlocked. In order to extend the length of overlap between the channel members and thereby increase the flexibility in locating the box along the length of the assembly, hanger bar assembly 10 may further include an extension member 50.
Referring to Figures l, 9A, 9B and l O, extension member 50 has a cross-sectional profile similar to that of channel member 20, 22. Extension member 50 may also include a gripping element 40 formed on its engagement surfaces in a mannersimilar to channel members 20, 22 described above. Extension member 50 may be rigidly secured to the end of one of the channel members by way of a connector 52.
Connector 52 is preferably a U-shaped member which is welded to a first 24' and a second 25' sidewall of extension member 50 at various points 53. A side portion 51 of connector 52 projects beyond the side edge of the extension member 50 and provides attachment points for securing extension 50 to side walls 24 and 25 of one of the channel members. In the preferred embodiment, connector 50 includes a clearance hole 54a which permits a fastening member 58, such as a screw, to pass therethrough and engage a threaded aperture 56a formed on channel member side wall 24. The connector portion secured to side wall 25 includes a threaded aperture 56b whichsupports fastening hardware 58 extending through a clearance hole 54b formed in side wall 25. As shown in Figure lO, side wall 25 with its indented central portion 108 provides clearance for fastening hardware 58 attached to side wall 24 thereby allowing substantially free longitudinal movement between channel members 20, 22.
CA 022~4236 l998-ll-l8 In the prerelled embodiment, channel members 20,22 have a length to permit assembly 10 to be used without the need for extension member 50 in applications having joist spacings of 16 inches on center. However, in order to permit hanger bar assembly 10 to be effectively employed in applications with joist spacings of 24 inches on center, extension member 50 may be employed. Joist spacings of 16 or 24 inches on center are the most commonly found spacings in typical construction. Accordingly, extension member 50 permits assembly 10 to be m~nllf~ctured with channel members20,22 of one length yet still accommodate a wide range of joist spacings. In addition, it is within the contemplation of the present invention, that the channel members 20,22 and extension member 50 may be produced in a wide range of lengths in order to suit a variety of applications.
Referring now to Figures 1, and 11-14, hanger bar assembly 10 further includes a pair of spacers 70 which are slidably engageable with channel members 20,22.
Spacers 70 support assembly 10 above the inner ceiling sheathing surface 120 prior to installation of joist ~ng~ing members 60. Spacers 70 align assembly 10 such thatwhen hanger bar assembly 10 is secured to the joist, the front face of the outlet box 100 will be substantially flush with the exterior surface of the ceiling sheathing.
Spacers 70 are preferably formed so they may be snap fit onto channel members 20,22 and their specific location on the channel members may be adjusted by sliding spacers 70 along their corresponding channel member. This ability to specifically locate spacers 70 permits hanger bar assembly 10 to be used in a wide variety of applications, including those employing wooden I-beam joists 118, as shown in Figure 14. Such I-beam constructor is being used more and more frequently in resi(lenti~l construction as the popularity of engineered lumber, inclll(ling wooden I-beams grows.
Spacers 70 are both similarly formed and include a transverse member 72 having a shape similar to the profile of channel member upper wall 23 and the opposed end formed by flanges 26. Transverse member 72 of one of spacers 70 abuts channel CA 022~4236 1998-11-18 member upper wall 23 of one channel member and the transverse member 72 of the other spacer abuts the flange end of the other channel member. Preferably, three legs 74 extend downwardly from transverse member 72. Spaced clip members 76, 78 extend upwardly from opposed ends of transverse member 72 and are shaped to permit one of channel members 20, 22 to fit therebetween. Clip members 76, 78 are somewhat resilient so that they can be slightly deformed to permit them to snap fit onto the corresponding channel member. Clip member 76 is sized to extend over a channel member size wall 24 and clip over a corner 27. Clip member 78 is sized to extend vertically along side wall 25 and clip onto one of the U-shape;l structures 110.
Spacers 70 support hanger bar assembly 10 above the ceiling cover such that when the joist engaging devices are driven into the joist and outlet box attached to the assembly will be substantially flush to the outer surface of the ceiling. However, since outlet boxes of various depths and ceiling covers of various thickness are commonly employed, it is desirable to provide a way to adjust the length of the spacers to fit a particular application. In the preferred embodiment, legs 74 may be adjustable by including a series of vertically spaced notches 80 which divide legs 74 into various segments 80a best shown in Figures 11 and 13. Notches 80 provide a fracture point which permits bottom portions of legs 74 to be incrementally removed thereby adjusting the length of spacer 70.
In order to provide additional support for the segmented leg portions, spacers 70 preferable include a plurality of webs 84 extending between legs 74 as shown in Figures 11 and 12. Webs 84 tie the segmented portions in the same horizontal plane together. Therefore, when adjusting the length of legs 74 all segments in a particular horizontal plane may be removed together. In addition, each notch 80 may include an indicia 82 which indicates the type of box and ceiling material so that an installer will easily know which portion of leg, if any, to remove. Such indicia 82 may be inscribed on webs 84.
, CA 022~4236 1998-11-18 Although the illustrative embodiments of the present invention have been described herein with reference to the accompanied drawings, it is to be understood that the invention is not limited to those precise embodiments and that various other changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention.
FIELD OF INVENTION:
The present invention relates generally to a hanger bar assembly for supporting electrical fixtures. More particularly, the present invention relates to a hanger bar assembly having telescopically engaged channel members having uniform cross-sectional profiles and that are engagable with each to restrict the relative motion of the channel members upon securement of an electrical outlet box to the channel members.
BACKGROUND OF THE INVENTION:
In order to secure electrical fixtures such as lights and fans in ceilings, a hanger bar device is typically employed. It is very important that a fixture be adequately supported in the ceiling since improper support could lead to the fixture breaking away from the ceiling. Ceilings are typically constructed of structural members including a series of spaced joists which are covered by lathe and plaster or a gypsum wallboard often referred to as drywall. The ceiling covering material or sheathing is not designed to support loads perpendicular to its surfaces. Therefore, in order to suspend electrical fixtures from a ceiling, the fixture's weight must be supported by the joists. To achieve this, a fixture may be secured directly to a joist, however, this limits the range of locations where the fixture may be placed. Such a limitation is problematic since it is often desirable to place the fixture in a specific position on the ceiling. Therefore, if no joist is adjacently positioned to the desired location, direct joist connection is not possible. A preferred solution for supporting electrical fixtures in the ceiling is the use of a hanger bar assembly. The hanger bar allows for the joists to be used for supporting an electrical fixture while still providing flexibility in positioning.
Hanger bar assemblies are typically extensible telescopic members that are disposed in between the ceiling joists and are securable thereto. An assembly's length, therefore, is adjustable to accommodate various joist spacing distances. Electrical outlet boxes, junction boxes and the like are then secured to the transverse members of CA 022~4236 1998-11-18 the assembly. Such electrical boxes provide a termination point for electrical wiring as well as an attachment point for the electrical fixture. Typically the outlet box can be positioned at various points along the length of the members in order to properly position the fixture attached thereto. In conventional construction a cut out is made in the ceiling covering material in order to provide clearance for the electrical outlet box, thereby allowing the fixture to be secured to the outlet box.
The outlet box once secured to the hanger bar assembly is typically used to support the electrical fixture. The National Electric Code sets a maximum weight that an outlet box may support. Outlet boxes may either support lighting fixtures weighing up to 50 Ibs. or ceiling fans weighing up to 35 lbs. Fixtures exceeding these weight limits must be supported independently of the box such as directly to the joists or other structural member.
Hanger bar assemblies can be divided into two general categories, standard and heavy duty and are distinguishable by the amount of weight they can safely support.
Standard hanger bars are typically used to support lightweight lighting fixtures which are generally less than five pounds.
An adjustable support for use with old work applications is described in U.S.
Patent 2,670,919 to Esoldi. The support includes a pair of interlocking channel members having uniforrr. U-shaped profiles. The channels are aligned such that the base portion of the channels form the top and bottom of the support. The bases include spaced slots which permit a prying tool to be inserted therein to adjust the length of the support. The channels require a pair of relatively narrow end straps to hold them and which permit longitudinal movement of the channel members relative to each other but prevent independent lateral movement of the members. The channelsare only secured together by the straps, thereby resulting in only limited resistance to static and dymanic loadings. A supporting strap is slidably disposed between the two~
end straps and is capable of supporting an outlet box. Such that upon the tightening of -T ~
CA 022~4236 1998-11-18 the box to the strap the channel members are clamped together. The supporting strap however, only engages a relatively small section of channel.
In addition, the only two relatively thin edges of the channels are brought intoengagement when the support strap is tightened. Therefore, such a design would be susceptible to slippage between the channels under the cyclic vibrational loads of a fixture such as a ceiling fan. Accordingly, this device is typically used to support relatively lightweight fixtures. In addition, since triangular spikes are used on each end of the support to engage the ceiling studs, an the force required to drive the projections increases as the width of the triangular projection increases. Therefore, it would be very difficult for an installer to be certain from feel alone that the projections where inserted a proper distance into the joists. If such a device were used in an old work application it would be difficult to visually determine if proper engagement had occurred.
U.S. Patent No. 2,925,236 to Cook et al. discloses a standard duty hanger bar assembly. The assembly includes telescopically engagable slotted channel memberspositionable between two ceiling joists. A box carrier is inserted in the channel members and has guide prongs extending from the slots. An outlet box is insertable over the prongs and is secured to the assembly by a box fastener which is securable to the box carrier by a threaded bolt. Upon the tightening of the bolt, a portion of the outlet box and a portion of the channel members are clamped together between thebox carrier and fastener, thereby securing the box to the assembly. The box carrier, however, only engages a small amount of channel section thereby providing a relatively small clamping area.
Heavy duty hanger bars are typically employed for supporting heavy lighting fixtures up to 50 Ibs. and ceiling fans weighing 35 lbs. Ceiling fans require high load bearing supports not only due to their weight but also due to the torque and vibrational forces that are generate by the rotation of the motor and fan blades. Relatively small weight differences between the blades of a ceiling fan can produce rotational ,, CA 022~4236 1998-11-18 imbalances leading to large vibrational forces. Therefore, a heavy duty hanger bar is required when suspending electrical fixtures such as ceiling fans.
Heavy duty hanger bars assemblies must be able to maintain their rigidity and length under high load situations. A load acting perpendicular to the length of the telescopic members tends to deflect the assembly toward the direction of the load. The degree of deflection increases when the members are free to move relative to each other as the members tend to be pulled apart by the load. Under certain circumstances, the deflection could be to such a degree that the members could be pulled completely apart resulting in the rt?lease of the outlet box and fixture attached thereto. Therefore, it is important that once the assembly is installed the members be secured so that they resist motion between themselves.
Heavy duty hanger bars may be designed for installation in new work or old work applications. New work applications include installations where the ceilingcovering material has not yet been installed and access to the joists is available. This may occur in situations such as new construction or renovations where the ceiling material has been removed. Old work applications include installations where theceiling covering material is already installed and the hanger bar needs to be inserted into an outlet box clearance opening cut into the ceiling. In such applications access to the joists is typically extremely limited. This situation is typically found when a ceiling fan is to be installed in a location where a ceiling lighting fixture had previously been installed.
Hanger bar assemblies capable of supporting loads such as ceiling fans and adapted for use in old work applications have been disclosed in U. S. Patent Nos.
5,150,868 to Keaden; 5,044,582 to Walters; and 4,463,923 to Reiker.
Reiker discloses a heavy duty junction box hanger assembly including a brace having two elongated members that are threadedly coupled such that relative rotation of one member with respect to the other causes the hanger assembly to expand or CA 022~4236 1998-11-18 contract. Thus, the length of the assembly is maintained by the engagement of the threaded coupling. The ends of the brace include spikes which engage the joist when the members are expanded. In order to install the assembly, expansion of the brace requires an installer to manually turn one of the members until the brace engages the S joists. This is a time-consuming task especially in situations having a large distance between the joist In addition, Reiker discloses a multi-component apparatus for securing the outlet box to the brace. First a two-part bracket must be secured to the brace and then the outlet box must be secured to the bracket assembly. This mounting method is time consuming and expensive to manufacture due to the various components involved.
The device disclosed in Keaden is similar to Reiker in that two members are threadedly engaged and expandable by rotation of one member with respect to the other. Hereto the length of the assembly is provided by the engagement of the threaded coupling. Keaden, however, addresses one of the problems associated with Reiker by employing a quick release mechanism that allows the members to extend freely without the need for rotation. The quick release mechanism releases the members from the normal threaded interconnection. Once released, the members canbe expanded relatively quickly. In order to achieve this quick release capability, however, the device requires the use of a special nut assembly having various segments and a spring. The nut is designed to either clamp down for threaded engagement or expand for quick release position depending on which direction the members are moved. The Keaden design, therefore, is fairly complex requiring several components in order to achieve its benefits.
In addition to the various components required to achieve the quick release function, the Keaden design also requires the use of a separate piece in order to attach the outlet box to the transverse brace. Keaden discloses the use of a U-shaped saddle bracket that rests on top of the brace and is securable to an outlet box by way of fastening hardware.
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CA 022~4236 1998-11-18 Walters discloses slidably telescopically eilgageable tubes. The bottom walls ofthe tubes have apertures therein. The apertures permit a prying tool to be inserted therein in order to expand the tubes, thereby forcing teeth disposed at both ends of the brace into the joists. In order to prevent the members from shifting under the load of the fixture, a spring bias roller is employed. The roller bears down on the upper surface of the inner tube thereby creating constant lateral pressure. The force of the roller, however, acts over only a relatively small area. Additionally, the spring force is susceptible to weakening over time. Both of these factors create the possibility that slippage might occur allowing the tubes to shift, thereby releasing the teeth from the joist. In such a situation the only support would be provided by flanges which would be resting on and supported entirely by the ceiling. As previously stated, ceilings are not typically designed to support such loads, and therefore, the fixture could possibly fall from the ceiling.
In addition, the Walters design requires the use of a knurled tension wheel, a spring and a housing which supports the assembly in order to restrict the relative motion of the members. Furthermore, Walters discloses a separate component for supporting an outlet box to the tubes comprising a bracket which is adapted to straddle over the upper end of the outer tube and which is connected to a second bracket which is adapted to ride on the bottom portion of the outer tube. Mounting bolts extend through both brackets into an outlet box which is secured in a conventional manner by nuts and bolts. These extra components increase the manufacturing costs of the assembly.
Accordingly, it would be desirable to devise a hanger bar assembly capable of supporting heavy loads such as ceiling fans that can be quickly installed and relatively simple to produce as well as being sufficiently rigid to resist vibrational forces under the heavy load of a fixture.
I
CA 022~4236 1998-11-18 SUMMARY OF THE INVENTION:
It is an object of the present invention to provide a hanger bar assembly for rigidly supporting an outlet box between spaced apart support elements.
It is a further object of the present invention to provide a hanger bar assemblyincluding a pair of interlocking telescopically engageable channel members which may be adjusted to an operating length and clamped to prevent relative channel member motion.
It is yet a further object of the present invention to provide a hanger bar assembly including having spacers slidably engageable along the length of the channel members for properly spacing the hanger bar assembly in the ceiling.
It is still a further object of the present invention to provide a hanger bar assembly including a joist engaging device which provides an installer with positive notice of proper engagement.
In the efficient attainment of these and other objects the present invention provides a hanger bar assembly for supporting an outlet box between spaced apartsupport elements including a support bar including a first and second telescopically extendable elongate channel members. Each channel member has an upper wall and afirst and second space side walls extending therefrom and defining a channel interior.
At least one of the side walls of each of the first and second channel members has an inwardly turned flange. The first and second channel members are longitudinally alignable such that the flange of the first channel member is engageable along atransverse extent of the second channel member upper wall. The flange of the second channel member is engageable along a transverse extent of the first channel member upper wall. A clamping device for urging the flanges into force engagement with the transverse extent of a corresponding channel member is also provided, thereby _ .
CA 022~4236 1998-11-18 restricting movement between the first and second channel members. Additionally, a securement device is provided for securing the support bar to the spaced supportelements.
In a preferred embodiment the hanger bar assembly joist engaging devise includes at least one spike member extending from opposing ends of the hanger bar assembly. The spikes have an elongate portion having a substantially uniform cross-section which terminates in a tapered endpoint. In addition, a pair of spacers for properly positioning the hanger bar assembly with respect to the support elements is preferable provided. The spacers are slidably attachable to opposed ends of the support bar, and each spacer is positionably adjustable along a length ofthe channel member to which the spacer is attached.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure I is a perspective view of the hanger bar assembly of the present invention.
Figure 2 is a cross-sectional view of the hanger bar assembly of the present invention with an outlet box secured thereto.
Figure 3 is a cross-sectional view of the assembly taken along line III-III of Figure 1.
Figure 4 top planar view of the hanger bar assembly.
Figure 5 is a elevational end view of one of the channel members.
Figure 6 is a detail cross-sectional view of an embodiment of the gripping element of the present invention taken along line VI-VI of Figure 5.
Figure 7 is a detail cross-sectional view of a preferred embodiment of the gripping element of the present invention.
Figure 8 is a perspective view of a preferred embodiment of a prying tool of thepresent invention.
Figure 9A is a perspective view of a channel member and extension member of the present invention.
CA 022~4236 1998-11-18 Figure 9B is an elevational end view of the extension member and connector of the present invention.
Figure 10 is a cross-sectional view ofthe interlocked channel members with the connector attached thereto taken along line X-X of Figure 1.
Figure 11 is an elevational front view of a spacer of the present invention.
Figure 12 is an elevational end view of a channel member having a spacer of Figure 11 attached thereto.
Figure 13 is an elevational side view of the hanger bar assembly of Figure 1.
Figure 14 is an elevational side view of the hanger bar assembly of Figure 1 in combination with an I-beam support member.
DETA~LED DESCRIPTION OF THE PREFERRED EMBODIl~'fENT
The hanger bar assembly of the present invention is adapted to support relatively heavy electrical fixtures such as ceiling fans in "old work" applications.
Ceiling fans, in addition to being relatively heavy, typically create cyclic loadings and vibrational forces due to the rotation of the motor and fan blades. Such forces must be adequately supported in order to ensure the fixture does not separate from the ceiling support structures to which it is attached. The hanger bar assembly of the present invention provides support for such fixtures as ceiling fans by maintaining its rigidity in configuration even under relatively high loadings.
Referring to Figure 1, the hanger bar assembly 10 formed in accordance with the preferred embodiment of the present invention is shown. Hanger bar assembly 10 includes a pair of channel members 20, 22, stud engaging members 60 and spacers 70.
Assembly 10 is adapted to be employed in "old work" applications where the ceiling covering material such as drywall or plaster has already been attached to the ceiling joists. However, it is conceivable that assembly 10 could also be used in "new work"
applications in which the joists are exposed and accessible.
Hanger bar assembly 10 is positionable between spaced apart ceiling joists (not shown) and securely engageable therewith. As shown in Figure 2, an outlet box, CA 022~4236 1998-11-18 junction box or the like 100 may be secured to the hanger bar assembly 10 by a U-bolt and nut combination 102, 104, in a manner which will be described in detail below.
Once the box is secured, an electrical fixture (not shown), such as a ceiling fan, may then be secure to the outlet box in a manner well known in the art. The hanger bar S assembly 10 and the joists provide the necessary support for the fixture.
Referring additionally into Figures 3 and 4, channel members 20, 22 are telescopically engageable elongate members which form a support apparatus. Each channel member 20, 22 is freely slidable with respect to the other, thereby permitting the length of hanger bar assembly 10 to be easily adjusted. In old work applications, hanger bar assembly 10 is preferably inserted up in the ceiling i.e., above the wallboard or plaster sheathing, through a cut out opening in the sheathing which is similar in sized to the perimeter of the outlet box being installed. This creates a relatively small space through which hanger bar assembly 10 must pass. Accordingly, assembly 10 is preferably collapsed to approximately its shortest length, as shown in Figure 4, upon insertion into the ceiling in order to facilitate installation. Once inside the ceiling, channel members 20, 22 may be quickly and easily expanded to an initial extension length substantially equivalent to the distance between the ceiling joists. Final expansion of channel members 20, 22 to an operating length results in joists eng~ging members 60 being secured to the joists.
As shown in Figures 2 and 3, channel members 20, 22 are preferably similarly formed interlocking members having substantially identical cross-sectional profiles.
Accordingly, the manufacturing of the hanger bar assembly is simplified and improved efficiency is obtained since only one part need be produced and cut into fini~hing lengths to form the two channel members.
Each channel member 20, 22 has a generally square-shaped cross-section including an upper wall 23 and a first and second space side walls 24, 25 extendin&
downwardly therefrom. Both side walls 24, 25 have inturned flanges 26 having spaced offset ends 30. Ends 30 define a slot 32 which extends the length of the channel CA 022~4236 1998-11-18 member. Side walls 24, 25 are joined to upper wall 23 and flan~es 26 by rounded corners 27. Channel members 20, 22 may be interlocked with each other by aligning the channel members end to end with one channel inverted with respect to the other and moving the channel members together such that a portion of each channel slides within the other. Channel members 20, 22 are so configured such that when they are interlocked a significant portion of each channel engages the other channel. As shown in Figure 3, flanges 26 of each channel member 20, 22 abut a transverse extent of the corresponding channel member over the length of assembly lO in which the channelmembers interlock.
When an electrical fixture is secured to hanger bar assembly lO, the resultant load acting downwardly thereon tends to bow the assembly pulling the channel members apart. If the channel members, once installed, were permitted to move relative to each other, this tendency to bow would not be restricted, and the resultant sagging, would present an opportunity for the channel members to slip apart and release the outlet box. If this were to occur, the fixture could come loose from the ceiling leading to a potentially hazardous situation due to the weight of the fixture.
However, by restricting relative movement between the channel members, the rigidity of the hanger bar assembly is increased, and its tendency to bow downwardly is greatly reduced. Additionally, in ceiling fan applications, the hanger bar assembly experiences torques and vibrational forces as well as static vertical loadings. A hanger barassembly's resistance to these dynamic forces is also augmented when the rigidity of the assembly is increased. In the present invention, the requisite rigidity is obtained by preventing relative movement between channel members 20, 22 by way of the forcedengagement of flanges 26 with the channel member upper walls 23 as described in detail below.
In the preferred embodiment, opposed flanges 26 and channel upper wall 23 are urged into forced engagement when outlet box lO0 is secured to hanger bar assembly lO. As shown in Figure 2, outlet box lO0 is secured to hanger bar assembly lO by U-bolt 102 which is placed over hanger bar assembly lO such that it straddles I
CA 022~4236 1998-11-18 channel members 20, 22. U-bolt 102 is sized such that it extends through apertures 106 formed in the back wall of outlet box lO0. Such apertures 106 are typically formed in standard outlet boxes in accordance with industry practice and standards. Nutfasteners 104 secure outlet box 100 to hanger bar assembly 10 and also provide the clamping force which urges flanges 26 and channel member upper walls 23 together, thereby restricting longitudinal movement between channel members 20, 22.
In the plere--ed embodiment, this forced engagement occurs adjacent the four corners 27 of channel members 20, 22. Flanges 26 of each channel member 20, 22 engage the other channel member over a transverse extent of an adjacently opposed portion of upper wall 23. As a result of the transverse and longitudinal dimensions of flanges 26, a substantial area of interference is created between channel members 20, 22. The clamping force generated upon securement of outlet box 100, therefore, acts over a significant area providing hanger bar assembiy lO with the ability to resist slippage between channel members 20, 22 even under the high loads and vibrationsgenerated by fixtures such as ceiling fans.
In order to increase the effectiveness of the clamping force, at least one of the channel members 20, 22 may preferably include a gripping element 40 formed alongthe length of the channel on the surfaces where the channels overlap and are brought into forced engagement upon securement of outlet box 100. These surfaces, shown in Figure 5, include the inside surface of flange 26 attached to side wall 24, the outer surface of the flange 26 attached to side wall 25, the inside corner formed by the junction of upper wall 23 and side wall 24, and an exterior portion of upper wall 23 adjacent side wall 25. The gripping element 40 may include a plurality of longitudinally spaced groves 42 as shown in Figure 6. Grooves 42 form an irregular non-smooth surface which increases the frictional coefficient of the engagement surfaces. This maximizes the resistance to slippage between channels for a givenclamping force. In an alternative embodiment, both channels 20, 22 may include agripping element 40 along their lengths.
CA 022~4236 1998-11-18 In a preferred embodiment shown in Figure 7~ gripping element 40' may include a plurality of spaced ridge-like projections 44, formed on channel surfaces brought into forced engagement described above. Projections 44 are preferably knurls and may be formed in a manner well known in the art. In an alternative preferred embodiment, knurls may be formed on the engagement surfaces of both channel members 20, 22.
In order to increase the rigidity of channel members 20, 22, side wall 25 of each channel member preferably includes a generally M-shaped cross-sectional profile.
As shown in cross-section in Figure 5, side wall 25 has a somewhat indented central planar portion 108 ending in raised U-shaped structures 110. Such a configuration increases the ability of side wall 25 to resist vertical loadings and moments thereby increasing hanger bar assembly's 10 overall ability to resist such forces.
When channel members 20, 22 are interlocked, both vertical and transverse movement between the channel members is restricted. Vertical movement is prevented by the general engagement between backwalls 23 and flanges 26 of channel members20, 22. Transverse movement is prevented by the cooperation between flanges 26 and a longitudinally extending track 46 formed in upper walls 23 of each of channel members 20, 22. As shown in Figure 3, tracks 46 are formed by an offset portion of upper wall 23. Each track has a substantially planar bottom run 48 sized to receive a flange 26 from a corresponding channel member. Track 46 is bounded by side walls49a, 49b formed by a lower portion of sidewall 24 and a diagonally extending transition portion which extends outwardly and upwardly from track run 48, respectively. Accordingly, when outlet box 100 is clamped to hanger bar assembly 10, channel members 20, 22 are longitudinally, transversely and vertically locked such that the rigidity of hanger bar assembly 10 is greatly enhanced. Furthermore, by incorporating the transverse interlocking device, i.e., track and flange, into the profile of the channel members no additional components are required, thereby reducing m~nuf~cturing and assembly costs.
.~ .
CA 022~4236 1998-11-18 In addition to providing a rigid support structure, the manner of interlocking of the two channel members 20, 22 permits the channels to be expanded by an installer using only one hand. This is especially significant in old work applications where once hanger bar assembly 10 is placed in the ceiling access thereto is limited. When S channels 20, 22 are interlocked one side wall of the hanger bar assembly is formed by one portion of a channel member with the other hanger bar assembly side wall being formed by a portion of the other channel member. Therefore, when the installer wraps a hand around channel members 20, 22, the installer can move one channel in one direction with their thumb and the other channel in the opposite direction with the other fingers, thereby expanding hanger assembly 10. In this manner, an installer may manually expand assembly 10 to a length such that the joist engaging membf~rs 60 abut the joists. Further expansion of assembly 10 to its operating length, resulting in its proper securement to the joists, is provided by further expansion of hanger bar assembly 10 by way of slots 34 and a prying tool.
With reference to Figures 3 and 4, channel members 20, 22 preferably include a plurality of longitudinally spaced elongate slots 34 formed through upper wall 23. Slots 34 provide a means for telescopically expanding hanger bar assembly 10 to an operating length such that joist engaging members 60 are secured in the joists. When channel members 20, 22 are interlocked one channel member is inverted with respect to the other thereby placing slots 34 of each member in spaced vertical alignment. As shown in Figure 3, upper wall 23 of one channel member substantially forms a top wall 36 of hanger bar assembly 10 and upper wall 23 of the other channel member substantially forms an assembly bottom wall 38. Slots 34 are sized to receive a prying tool which may be used to urge channel members 20, 22 apart thereby expanding the length of hanger bar assembly 10. Channel members 20, 22 may then be expended byvertically inserting the prying tool through a pair of aligned slots 34 in each channel member and rotating the tool about a horizontal axis perpendicular to the length of Xanger bar assembly 10. Expansion of hanger bar assembly 10 to the operating length forces joist eng~gin~ members 60 into the joists thereby securing hanger bar assembly 10 thereto. Slots 34 may further include rounded end portions 35 which will cradle a CA 022~4236 1998-11-18 prying tool 90 inserted in slots 34 in order to keep the prying tool in proper alignment to the axial line of action required to extend hanger bar assembly 10. In the preferred embodiment shown in Figure 8, prying tool 90, which may be provided with hanger bar assembly 10, may consist of a rod having a diameter slightly less than the radius of the slots rounded end portion 35. Alternatively, a similarly sized screw driver or other rigid elongate device may be employed to provide the prying function.
Referring to Figures 1 and 4, joist engaging members 60 are disposed at the distal ends of each channel member 20, 22 and extend from opposite sides of hanger bar assembly 10. Joist engaging members 60 are preferably rigidly secured to upper wall 23 and to flanges 26 of each channel member 20,22. Each joist engaging member 60 includes a pair of laterally spaced spikes 62 extending longitudinally outwardly from channel member to which it is attached. Spikes 62 are separated by a web 63 which is preferably welded to the corresponding channel member. Spikes 62 are adapted to be driven into the joists upon the outward expansion of channel members 20, 22 thereby fixedly securing hanger bar assembly 10 at both ends.
Each spike 62 preferably includes an elongate portion 64 having a uniform cross-section which terminates in a tapered end point 66. Such a configuration permits an installer of a hanger bar assembly to easily ascertain when spikes 62 are fully inserted within the joist. Upon the expansion of channel members 20, 22, spike end points 66 first engage the joists. Once the relatively short taper end points 66 enter the joists, the force exerted on prying tool 90 required to drive the remainder of spikes 62 further into the joist is substantially constant due to the uniform cross-section of elongate portion 64. When spikes 62 are fully inserted, the distal end of the channel members will butt the joist at which point the installer can easily sense that spikes 62 are fully engaged.
In contrast, joist engaging devices of the prior art typically include a triangular shape member having a varying cross-section throughout its length. Therefore, the force required to urge joist engaging member increases throughout the length of the CA 022~4236 1998-11-18 member. Accordingly, an installer would be uncertain if the joist engaging device has been fully engaged and the support member is butting the joist or if still more force is needed to drive in the device.
The manner in which outlet box lO0 is secured to hanger bar assembly 10 permits outlet box 100 to be located on any position along the length of assembly 10.
However, in order to achieve the clamping function, the box must be secured to assembly 10 at a point where channel members 20, 22 overlap and are interlocked. In order to extend the length of overlap between the channel members and thereby increase the flexibility in locating the box along the length of the assembly, hanger bar assembly 10 may further include an extension member 50.
Referring to Figures l, 9A, 9B and l O, extension member 50 has a cross-sectional profile similar to that of channel member 20, 22. Extension member 50 may also include a gripping element 40 formed on its engagement surfaces in a mannersimilar to channel members 20, 22 described above. Extension member 50 may be rigidly secured to the end of one of the channel members by way of a connector 52.
Connector 52 is preferably a U-shaped member which is welded to a first 24' and a second 25' sidewall of extension member 50 at various points 53. A side portion 51 of connector 52 projects beyond the side edge of the extension member 50 and provides attachment points for securing extension 50 to side walls 24 and 25 of one of the channel members. In the preferred embodiment, connector 50 includes a clearance hole 54a which permits a fastening member 58, such as a screw, to pass therethrough and engage a threaded aperture 56a formed on channel member side wall 24. The connector portion secured to side wall 25 includes a threaded aperture 56b whichsupports fastening hardware 58 extending through a clearance hole 54b formed in side wall 25. As shown in Figure lO, side wall 25 with its indented central portion 108 provides clearance for fastening hardware 58 attached to side wall 24 thereby allowing substantially free longitudinal movement between channel members 20, 22.
CA 022~4236 l998-ll-l8 In the prerelled embodiment, channel members 20,22 have a length to permit assembly 10 to be used without the need for extension member 50 in applications having joist spacings of 16 inches on center. However, in order to permit hanger bar assembly 10 to be effectively employed in applications with joist spacings of 24 inches on center, extension member 50 may be employed. Joist spacings of 16 or 24 inches on center are the most commonly found spacings in typical construction. Accordingly, extension member 50 permits assembly 10 to be m~nllf~ctured with channel members20,22 of one length yet still accommodate a wide range of joist spacings. In addition, it is within the contemplation of the present invention, that the channel members 20,22 and extension member 50 may be produced in a wide range of lengths in order to suit a variety of applications.
Referring now to Figures 1, and 11-14, hanger bar assembly 10 further includes a pair of spacers 70 which are slidably engageable with channel members 20,22.
Spacers 70 support assembly 10 above the inner ceiling sheathing surface 120 prior to installation of joist ~ng~ing members 60. Spacers 70 align assembly 10 such thatwhen hanger bar assembly 10 is secured to the joist, the front face of the outlet box 100 will be substantially flush with the exterior surface of the ceiling sheathing.
Spacers 70 are preferably formed so they may be snap fit onto channel members 20,22 and their specific location on the channel members may be adjusted by sliding spacers 70 along their corresponding channel member. This ability to specifically locate spacers 70 permits hanger bar assembly 10 to be used in a wide variety of applications, including those employing wooden I-beam joists 118, as shown in Figure 14. Such I-beam constructor is being used more and more frequently in resi(lenti~l construction as the popularity of engineered lumber, inclll(ling wooden I-beams grows.
Spacers 70 are both similarly formed and include a transverse member 72 having a shape similar to the profile of channel member upper wall 23 and the opposed end formed by flanges 26. Transverse member 72 of one of spacers 70 abuts channel CA 022~4236 1998-11-18 member upper wall 23 of one channel member and the transverse member 72 of the other spacer abuts the flange end of the other channel member. Preferably, three legs 74 extend downwardly from transverse member 72. Spaced clip members 76, 78 extend upwardly from opposed ends of transverse member 72 and are shaped to permit one of channel members 20, 22 to fit therebetween. Clip members 76, 78 are somewhat resilient so that they can be slightly deformed to permit them to snap fit onto the corresponding channel member. Clip member 76 is sized to extend over a channel member size wall 24 and clip over a corner 27. Clip member 78 is sized to extend vertically along side wall 25 and clip onto one of the U-shape;l structures 110.
Spacers 70 support hanger bar assembly 10 above the ceiling cover such that when the joist engaging devices are driven into the joist and outlet box attached to the assembly will be substantially flush to the outer surface of the ceiling. However, since outlet boxes of various depths and ceiling covers of various thickness are commonly employed, it is desirable to provide a way to adjust the length of the spacers to fit a particular application. In the preferred embodiment, legs 74 may be adjustable by including a series of vertically spaced notches 80 which divide legs 74 into various segments 80a best shown in Figures 11 and 13. Notches 80 provide a fracture point which permits bottom portions of legs 74 to be incrementally removed thereby adjusting the length of spacer 70.
In order to provide additional support for the segmented leg portions, spacers 70 preferable include a plurality of webs 84 extending between legs 74 as shown in Figures 11 and 12. Webs 84 tie the segmented portions in the same horizontal plane together. Therefore, when adjusting the length of legs 74 all segments in a particular horizontal plane may be removed together. In addition, each notch 80 may include an indicia 82 which indicates the type of box and ceiling material so that an installer will easily know which portion of leg, if any, to remove. Such indicia 82 may be inscribed on webs 84.
, CA 022~4236 1998-11-18 Although the illustrative embodiments of the present invention have been described herein with reference to the accompanied drawings, it is to be understood that the invention is not limited to those precise embodiments and that various other changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention.
Claims (27)
1. A hanger bar assembly for supporting an outlet box between spaced apart support elements comprising:
a support bar including a first and a second telescopically extendable elongate channel members, each of said first and second channel members having an upper wall and a first and second spaced side walls extending therefrom defining a channel interior, at least one of said first and second side walls of each of said first and second channel members having an inwardly turned flange, said first and second channel members being longitudinally alignable such that said flange of said first channel member is engageable along a transverse extent of said second channel member upper wall and said flange of said second channel member is engageable along a transverse extent of said first channel member upper wall;
a clamping device for urging said flanges of said first and second channel members into respective forced engagement with said transverse extents of said first and second channel members, thereby restricting movement between said first and second channel members, and a securement device for securing said support bar to said spaced support elements.
a support bar including a first and a second telescopically extendable elongate channel members, each of said first and second channel members having an upper wall and a first and second spaced side walls extending therefrom defining a channel interior, at least one of said first and second side walls of each of said first and second channel members having an inwardly turned flange, said first and second channel members being longitudinally alignable such that said flange of said first channel member is engageable along a transverse extent of said second channel member upper wall and said flange of said second channel member is engageable along a transverse extent of said first channel member upper wall;
a clamping device for urging said flanges of said first and second channel members into respective forced engagement with said transverse extents of said first and second channel members, thereby restricting movement between said first and second channel members, and a securement device for securing said support bar to said spaced support elements.
2. A hanger bar assembly as set forth in Claim 1, wherein said first and second channel members are transversely interlocking such that a portion of said first channel member is insertable within said second channel member and a portion of said second channel member is insertable within said first channel member interior.
3. A hanger bar assembly as defined in Claim 2, wherein each of said side walls of said first channel member includes an inwardly turned flange and wherein one of said flanges of said first channel member engages an inner surface of said second channel member and said other first channel member flange engages an outer surface of said second channel member.
4. A hanger bar assembly as defined in Claim 1, wherein said clamping device includes a U-shaped bolt member slidably positionable on said support bar and engageable with the outlet box, said clamping device further includes;
a fastening device securable with said U-bolt such that upon securing said fastening device to said U-bolt said first and second channel members are forcedtogether.
a fastening device securable with said U-bolt such that upon securing said fastening device to said U-bolt said first and second channel members are forcedtogether.
5. A hanger bar assembly as defined in Claim 4, wherein said first channel member includes a plurality of gripping elements formed along a length thereof, said gripping elements being engageable with a portion of said second channel member.
6. A hanger bar assembly as defined in Claim 5, wherein said gripping elements are formed on said flanges of said first and second channel members.
7. A hanger bar assembly as defined in Claim 5, wherein said gripping elements are formed on said transverse extent of said first and second channel members.
8. A hanger bar assembly as defined in Claim 6, wherein said gripping element includes a plurality of spaced protrusions.
9. A hanger bar assembly as defined in Claim 1, wherein said securement device includes at least one spike member extending from opposing ends of said hanger bar assembly for engagement with the support elements, and said at least one spike member includes an elongate portion having a substantially uniform cross-sectionterminating in a tapered endpoint for providing a means for allowing an installer to determine if said spike members are fully inserted in the support elements.
10. A hanger bar assembly as defined in Claim 9, wherein said securement device includes a plurality of spike members extending from opposing ends of said hanger bar assembly, said spike members being forceable into said support members thereby securing said hanger bar assembly thereto.
11. A hanger bar assembly as defined in Claim 1, wherein said upper walls of said first and second channel members include a plurality of longitudinally spaced slots sized to receive a prying tool to provide relative longitudinal adjustment of said first and second channel members and to force said securement device into the support elements.
12. A hanger bar assembly as defined in Claim 1, further including a pair of spacers for properly positioning the hanger bar assembly with respect to the support elements, said spacers being slidably attachable to opposed ends of said support bar, each spacer being positionably adjustable along a length of said channel member to which said spacer is attached.
13. A hanger bar assembly as defined in Claim 12, wherein each of said spacers includes a transverse member having a plurality of legs extending downwardly therefrom which are engageable with a sheathing material covering the support elements, said transverse member further including a pair of resilient spaced arms extending upwardly therefrom, said arms being securable to said channel member.
14. A hanger bar assembly as defined in Claim 13, wherein each of said legs includes a plurality of frangible segments which may be individually removed thereby adjusting the length of said legs in order to provide proper alignment of the hanger bar assembly.
15. A hanger bar assembly as defined in Claim 1, further including an extension member securable to one of said first and second channel members thereby extending the length thereof and permitting a length of said support bar to be increased to accommodate a relatively wide support element spacing.
16. A hanger bar assembly as defined in Claim 15, wherein said first and second channel members and said extension member each have substantially similar cross-sectional profiles.
17. A hanger bar assembly as defined in Claim 15, wherein said extension member includes a connector piece fixedly secured to said extension member, said connector piece having a longitudinally extending end portion fixably securable to one of said first and second channel members.
18. A hanger bar assembly as defined in Claim 1, wherein one of said side walls of each of said first and second channel members is substantially M-shaped in cross-section thereby providing increased structural support.
19. A hanger bar assembly as defined in Claim 1, wherein said first and second channel members have substantially similar cross-sectional profiles.
20. A hanger bar assembly for supporting an outlet box between spaced apart support elements comprising:
a support bar including a first and second telescopically extendable elongate channel members, each of said first and second channel members having an upper wall and a first and second spaced side walls extending therefrom defining a channel interior;
said upper wall of said first channel member defining a longitudinally extendingfirst track;
said first side wall of said second channel member having a a longitudinally extending member transversely retained within said first track, thereby preventing transverse movement between said first and second channel members;
a clamping device for urging said first and second channels into forced engagement, thereby restricting longitudinal movement; and a securement means for securing said support bar to said spaced support elements.
a support bar including a first and second telescopically extendable elongate channel members, each of said first and second channel members having an upper wall and a first and second spaced side walls extending therefrom defining a channel interior;
said upper wall of said first channel member defining a longitudinally extendingfirst track;
said first side wall of said second channel member having a a longitudinally extending member transversely retained within said first track, thereby preventing transverse movement between said first and second channel members;
a clamping device for urging said first and second channels into forced engagement, thereby restricting longitudinal movement; and a securement means for securing said support bar to said spaced support elements.
21. A hanger bar assembly of Claim 20, wherein said upper wall of said second channel member defines a longitudinally extending second track;
said first side wall of said first channel member having a a longitudinally extending member transversely retained within said second track, thereby preventing transverse movement between said first and second channel members.
said first side wall of said first channel member having a a longitudinally extending member transversely retained within said second track, thereby preventing transverse movement between said first and second channel members.
22. A hanger bar assembly of Claim 21, wherein said first side wall of said second channel member ends in an inwardly turned flange forming said longitudinally extending member.
23. A hanger bar assembly of Claim 22, wherein said first track has a substantially planar bottom surface and said flange is substantially planar and sized to be slideably received within said first track.
24. A hanger bar assembly of Claim 20, wherein said longitudinally extending member includes a transversely extending flange;
said first and second channel members are longitudinally alignable such that said flange of said second channel member is engageable along a transverse extent of said first channel member upper wall; and wherein said clamping device urges said flange into force engagement with said transverse extent of said first channel member upper wall, thereby restricting movement between said first and second channel members.
said first and second channel members are longitudinally alignable such that said flange of said second channel member is engageable along a transverse extent of said first channel member upper wall; and wherein said clamping device urges said flange into force engagement with said transverse extent of said first channel member upper wall, thereby restricting movement between said first and second channel members.
25. A hanger bar assembly for supporting an outlet box between spaced apart support elements comprising:
a support bar including a first and second telescopically extendable elongate channel members, each channel member having an upper wall and a first and secondspace side walls extending therefrom defining a channel interior, said side walls having inwardly turned substantially planar flanges;
said first and second channel members being longitudinally alignable such that said flanges of said first channel member engage said second channel member and said flanges of said second channel member engage said first channel member;
a clamping device for urging said flanges into force engagement with a corresponding channel member, thereby restricting movement between said first and second elongate members; and a securement device for securing said support bar to said spaced support elements.
a support bar including a first and second telescopically extendable elongate channel members, each channel member having an upper wall and a first and secondspace side walls extending therefrom defining a channel interior, said side walls having inwardly turned substantially planar flanges;
said first and second channel members being longitudinally alignable such that said flanges of said first channel member engage said second channel member and said flanges of said second channel member engage said first channel member;
a clamping device for urging said flanges into force engagement with a corresponding channel member, thereby restricting movement between said first and second elongate members; and a securement device for securing said support bar to said spaced support elements.
26. A hanger bar assembly as defined in Claim 25, wherein said upper walls of said first and second channel members include a plurality of longitudinally spaced slots sized to receive a prying tool to provide relative longitudinal adjustment of said first and second channel members and to force said securement device into the support elements.
27. A hanger bar assembly as defined in Claim 26, wherein said securement device includes at least one spike member extending from opposing ends of said hanger bar assembly for engagement with the support elements, said at least one spike member includes having an elongate portion having a substantially uniform cross-sectionterminating in a tapered endpoint for providing a means for determining if said spike members are fully inserted in the support elements.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US97707997A | 1997-11-24 | 1997-11-24 | |
| US977,079 | 1997-11-24 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2254236A1 true CA2254236A1 (en) | 1999-05-24 |
Family
ID=29550582
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2254236 Abandoned CA2254236A1 (en) | 1997-11-24 | 1998-11-18 | Hanger bar assembly |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2254236A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9583926B2 (en) | 2013-06-04 | 2017-02-28 | Thomas & Betts International Llc | Hanger bar |
-
1998
- 1998-11-18 CA CA 2254236 patent/CA2254236A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9583926B2 (en) | 2013-06-04 | 2017-02-28 | Thomas & Betts International Llc | Hanger bar |
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| Date | Code | Title | Description |
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