US3636340A

US3636340A - Air-handling ceiling channel structure

Info

Publication number: US3636340A
Application number: US850454A
Authority: US
Inventors: Gerard Edmund Mulvey
Original assignee: Individual
Current assignee: FLEXILLUME CANADA Ltd 165 STEELCASE ROAD EAST MARKHAM ONTARIO L3R 1G1 CANADA A CORP OF CANADA
Priority date: 1969-08-15
Filing date: 1969-08-15
Publication date: 1972-01-18
Anticipated expiration: 1989-01-18

Abstract

An air-handling channel structure for ceilings in which recessed channels are provided around lighting fixtures in the ceiling, and openings in the upper ends of the channels are connected to air delivery and return systems, each channel system being defined on one side by a ceiling support strut member, and on the other side by an inner frame member forming part of the lighting fixture, the strut and the frame members being formed separately, thereby enabling them to be provided with different finishes, and also enabling the ceiling and the strut members and the airhandling facilities to be erected and installed separately from the installation of the lighting fixtures. Locating means on the strut and frame members maintain those members in their desired spaced-apart positions.

Description

[ 1 Jan. 18,1972

1541 AIR-HANDLING CEILING CHANNEL STRUCTURE Gerard Edmund Mulvey, 36 Castle Frank Road, Toronto, Ontario, Canada 221 Filed: Aug. 15,1969

211 Appl.No.: 850,454

[72] Inventor:

52 us. on. ..240/9 R, 98/40 DL,240/51.11'R

3,502,860 3/1970 Mulvey ..240/9 3,506,822 4/1970 Mulvey.. ..240/51.11X

Primary Examiner-Louis R. Prince Assistant Examiner-Denis E. Corr Attorney-George A. Rolston [57] ABSTRACT An air-handling channel structure for ceilings in which recessed channels are provided aroundlighting fixtures in the ceiling, and openings in the upper ends of the channels are connected to air delivery and return systems, each channel system being defined on one side by a ceiling support strut member, and on the other side by an inner frame member forming part of the lighting fixture, the strut and the frame members being formed separately, thereby enabling them to be provided with different finishes, and also enabling the ceiling and the strut members and the air-handling facilities to be erected and installed separately from the installation of the lighting fixtures. Locating means on the strut and frame members maintain those members in their desired spaced-apart positions.

7 Claims, 6 Drawing Figures PATENTEflJmsmz 6,

SHEET 1 UF 2 GERARD E. MULVE Y PATENTEB Jun 8 m2 SHEET 2 OF 2 I N VEN'I UR GERARD E. MULVEY AIR-HANDLING CEILING CHANNEL STRUCTURE This invention relates to air-diffusing ceiling structures for use in buildings providing concealed diffusers associated with lighting fixture frames.

Air diffusers and return fixtures in the form of longitudinal slotted openings are well known in the air-handling art, and

. have been designed for arrangement in various parts of the ceiling, and in some cases, have been arranged and designed for attachment alongside the lighting fixtures in the ceiling. However, generally speaking such slotted diffusers and retum facilities have involved the use of long slotted openings in the ceiling which provide an unsightly and inartistic arrangement, breaking up the aesthetic design of the ceiling as a whole, and in addition, in some cases causing problems in the layout and arrangement of the ceiling structure. A further proposal has been the association of such slotted diffusers and return facilities together with the lighting fixtures such as light troffers which are customarily supported in such ceiling. Again, however, even when associated with such light troffers, the. diffusers have resulted in the arrangement of unsightly longitudinal openings along each side of the troffers.

Many of these disadvantages have been overcome by the use of light troffers having recessed frames designed and arranged specifically for association with air-handling facilities and provided with air-handling slots within recesses around the frame, which slots are concealed from view by being located and hidden within channel-shaped frame members arranged around the perimeter of the lenses of the light troffers. However, in this improved design, the channel-shaped troffer frames which were provided with the air-handlingslots were formed in a single integral extrusion of aluminum or plastic or the like material having means for attachment to the light troffer, and also having, in some cases, means for supporting the adjacent ceiling structure such as a ceiling tile, or aplaster ceiling or the like. In this prior design, the channel-shaped troffer frame, being of a single integral extrusion, was necessarily provided with auniform overall finish or coloring. In some cases, the architectural design ofthe ceiling has resulted in an unsightly clash between the coloring and design of the ceiling tile or plaster, and the coloring and'finish of'the-channel-shaped troffer frame. In addition, and more importantly, the erection and installation of a ceiling incorporatingsuch integral channel-shaped troffer frames has required that the entire light troffers and lighting fixtures be installed and positioned prior to the installation and erection of the ceiling structure itself, since the integral frame forrnedan important part of the overall ceiling. Such a-program of building construction is not always possible, particularly bearingin mind that the erection of the ceiling is most usually performedbya workman belonging to a different trade from that of the workman installing the electrical fixtures.

For these reasons, and other reasons relating to the economics of production and flexibility of design, it is now proposed according to the present invention to provide a ceiling support frame structure which, together with a separate troffer frame, defines a recessed channel around the light troffer, which channel incorporates within it slotted air-handling openings for difiusing of air and withdrawal of return air, the two sides of the channel being separate from one another, thereby permitting the use of different coloring and finishes on the ceiling-supportingportion and the troffer frameportion respectively, and also overcoming the problem of the installation of the ceiling and supporting frame by one group. of tradesmen, and the installation of the lighting fixtures by another group of tradesmen.

It is therefore a general objective of the present invention to provide a ceiling-supporting structure designed and adapted to be associated with light troffer lighting fixtures, and together therewith, providing and constituting a recessed channel around such lighting fixture, within which continuous air-handling openings are provided, .adapted for interconnection with air-handling conduits within the ceiling.

More particularly, it is an objective of the present invention to provide a ceiling supporting structure having the foregoing advantages which is adapted for erection, independently of thelightingfixtures and associated framework.

More particularly, it is an objective of the present invention to provide a ceiling structure having the foregoing advantages which provides. ceiling support bars, and means for attachment of such bars to the'fabric of the building for permanent support thereof, and also incorporating lighting fixture support flange members extending sideways therefrom for support of a lightingfixture frame adjacent thereto in spaced parallel relation thereby defining together with such lighting frame a recessed air-handling channel around such lighting fixture.

It will be understood that this is essentially a general outline only of the features and objectives of the invention, which invention will of course be subject to variations and changes such as come within thescope of the patent claims annexed hereto. i

The foregoing and other advantages will become apparent from the following description of a preferred embodiment of the invention which is given here by way of example only, with reference to the following drawings, in which like reference devices refer to like parts thereof throughout the various views and diagrams and'in which;

FIG. 1 is a lower perspective illustration of the ceiling supporting structure and a typical lighting fixture associated therewith in position in aceiling, with the air handling ducting and facilities shown in phantom form;

FIG. 2 is a section along the line 2' '2 of FIG. 1;

FIG. 3 is a section along the line 33 of FIG. 1;

FIG. 4 is a sectional illustration of an alternative embodiment, the position of the section corresponding to the section ofFlG. 2,

FIG. 5 is a sectional, illustration of a further alternative embodiment of the invention, the position of the section again corresponding to that of H6. 2, and

FIG. 6 is a section of the embodiment of FIG. 5 at its ends corresponding to the position of the section of FIG. 3.

Referring'now to FIG. 1, it will beseen that this is a general view of a ceiling in the course of construction, showing portions of afixed framework consisting of ceiling. struts or strut members S, which framework is adapted to be permanently located as part of the ceiling structure, and which may or may not incorporate means for supporting the adjacent ceiling covering material such as plaster, accoustic tile or the like, shown generally as reference C and which is supported in position at predetermined ceiling levels from the fabric of the building by conventional means such as wires or rods R. The struts S define a rectangular space in which is located the lighting fixture indicated generally as L, which is of course concealed within the ceiling, the only visible portion being the inner framework F andthe illuminated plastic panels P.

It will be seenthat the inner framework F of the lighting fixture is separated and spaced a predetermined distance from the ceiling struts S thereby defining between them a recessed channel which is devoid of any illumination, and being located around the perimeter of the brightly illuminated panels P, appears totally black when viewed from beneath. At certain points aroundthe framework F and struts S, longitudinal airhandling openings are arranged, suitable for attachment of airducting D and the outlet and return air boots B. The details of the air ducting .and air boots form no part of this invention, and those elements are in any case of conventional construction. In fact, in some cases in more advanced ceiling design, it is now becoming thepractice to dispense altogether with connections to individual air return facilities, by means of boots and the like, the interior of the ceiling being simply divided by partitions into air-return zones, the, air-handling openings in the-ceiling merely opening directly into such partition zones. Thus the practice. of the present invention which is directed specifically to the provision of such longitudinal air-handling channel openings in a concealed manneraround lighting fixtures and the like is equally applicable, whether. air connection 'boots are or are not to be used.

The lighting fixture L has slide and end walls as will readily be apparent by reference to FIG. 1 but will not be described in detail, herein since that fixture is essentially of conventional construction consisting merely of a housing or troffer and fluorescent tubes arranged in various locations so as to provide either a rectangular or square or even hexagonal or octagonal fixture depending upon the aesthetic design of the ceiling, these other construction details being omitted for the sake of clarity.

Referring now to FIGS. -2 and 3, illustrating sections around the structure shown in FIG. 1, it will be seen that the ceiling struts indicated generally as S are of continuous extruded construction, in this preferred embodiment, and each comprises a vertical sidewall-member 10, provided at its upper end with any suitable means of attachment for the wire or rail hangers R.' In this case, the attachment means consists of a continuous restricted groove ll in the sidewall member 10, which groove is adapted to make slidable gripping engagement with a cylindrical support member 12 attached at the lower end of each rod R, in known manner. .lust below such upper end edge of each of the sidewall members'l0, there is provided a transverse flange member l3 of a predetermined width, which, as will be explained in greater detail hereinafter, provides a means for locating the framework of the lighting fixture. In this particular embodiment, one or more longitudinal openings 14 are formed in each flange member 13 for the free passage of air and each flange member 13 terminates in an outer support ledge portion 15 for a reason to be described hereinafter. Adjacent the lower end of the sidewall member 10, there is provided an air director baffle member 16 of predetermined width for causing deflection of air passing around the same whereby to define a predetermined airflow pattern within the building.

As stated, the ceiling struts are designed to be permanently mounted and located in the ceiling in the building. For this purpose, in some cases, some form of support means can be provided on the struts for adjacent portions of the ceiling, although no such means are provided in the embodiment shown in FIG. 2. In this case, an adjacent portion of acoustic ceiling C is shown as merely abutting directly onto the outer face of the sidewall intermediate its upper and lower ends, and in many cases, it is found that this is entirely sufficient for the purpose.

As stated above, the frame members forming the framework F are formed entirely separately from the ceiling strut members S, and each comprises a sidewall portion 17, which may optionally incorporate air baffle means, such as a rib 18 shown in phantom, although the use of such air baffle members is entirely dependent upon the desired airflow pattern. At the upper edge of each of the sidewall members 17, a horizontal shoulder member 19 is provided to constitute a locating means as well as to define an upper ledge 20 adapted to support a plastic panel P of the lighting fixture L. The underside of shoulder 19 is adapted sealingly to overlie the ledge portion of the flange 13 as shown, for support thereof. In order to attach the housing or so-called troffer of the lighting fixture L, an attachment flange 21 extends upwardly from the shoulder I9, in a plane, offset from the plane of the sidewall I7, and lighting fixture L is shown as being attached by a screw 22 to each attachment flange. In this way, the entire area of panel P may be illuminated without peripheral or marginal darkened zones.

Referring now to FIG. 3, this illustrates the ceiling strut S and the frame member F along one end of the fixture L. The ceiling strut S will be seen to have the same sidewall member I0, air deflector baffle 16, and transverse locating flange 13. In addition, it is supported by the same groove 11 and cylindrical support member 12. However, it will be noted that no airhandling slots are provided in the flange member I3, since such slots are not normally provided along the ends of such a fixture and, in any case, ample air-handling openings can be provided by arranging them on each side of'the fixture. The end frame member F has essentially the same construction as that already. described and has a sidewall I7, a locating shoulder 19, and an attachment flange 21. The provision of the deflector bafile 16 at the end of the fixture L is regarded as necessary for providing a continuity of appearance around the entire extent of the lighting fixture, but otherwise performs no useful function.

The ceiling tile or other ceiling structure (not shown) merely abuts the outer surface of sidewall 10 as before. In this manner, a lighting fixture is provided in which the lens or plastic panel P is recessed relative to the ceiling in a manner which greatly improves its appearance. In addition, since the struts S and frame members'F which define the continuous channel around each fixture, are separate and unattached, they can have different surface finishes without difficulty which further improves the overall appearance.

- It will be understood that the design of the ceiling struts S and their interconnection in the ceiling and manner in which they support the acoustic tile or other ceiling material may vary widely and are independent of the scope of this invention.

. Thus in some cases the ceiling may be designed as a so-called luminous ceiling in which there is virtually no accoustic tile material at all, the entire ceiling being filled with lighting fixtures. In this case a basic supporting framework of parallel ceiling T-section bars (not shown) of known design may be hung in known manner spaced apart distances equal to the overall length of the lighting frameworks .L and their associated frames F and struts S. The struts S may be modified to incorporate an additional outer flange (not shown). to in terengage with the ceiling tees in any suitable manner to provide a finished appearance.

According to a further embodiment of the invention as shown in FIG. 4, provision may be made for a ceiling of plaster construction and in which the lighting units L are inserted from below and fastened in the ceiling before or after it is plastered. According to this embodiment, each of the ceiling struts S is provided with a lower sidewall 30, an intermediate horizontal shoulder portion 31 and an upper sidewall 32 located in a vertical plane offset with respect to the plane of the lower sidewall 30. A transverse flange member 33 extends horizontally from the upper sidewall 32, and is provided with elongated air-handling slots 34 therethrough. Flange 33 terminates in a generally cross-shaped structure having upper and lower strengthening ribs 35, and a horizontal bearing flange 36 and functions as a locating means to maintain the framework member F spaced apart inwardly from the respective struts S. The upper end of upper sidewall 32 is provided with an upstanding attachment rib 37 provided with a plurality of holes therethrough (not shown) for attachment of the conventional support members such as rods or wires R. In order to provide some support for the plaster of the ceiling, the lower sidewall 30 of ceiling strut S is provided with an outwardly directed upwardly angled flange member 38.

In this embodiment, the inner frame member F consists of the sidewall member 39 having a lower ledge portion 40 for supporting the plastic panels P thereon, and such a frame member F is provided with any suitable attachment means (not shown) along its upper edge 41 for attachment of support means such as the rods'or wires R. The lighting troffer or housing L is attached to each of the frame members F by any suitable means such as screws 42. In order to accurately locate each inner frame member F with regard to a respective one of the ceiling strut members S, the sidewall 39 of that frame member is provided with an inwardly directed locating rib 43 positioned at a predetermined height on the inner side of the base wall 39 so as to contact and engage the lower surface of the flange portion 36 of the horizontal flange 33. In this way the lower edges of

sidewalls

30 and 39 are usefully located in the same horizontal plane. The locating rib 43 also usefully sealingly engaging the portion 36 of the flange 33. Depending upon the airflow characteristics of the particular system, an airflow deflector baffle member such as baffle member 44 may be provided, the location and size of such a baffle member depending upon the desired airflow characteristics of the system. The air delivery or return boots B are mounted in position along the upper surface of the horizontal flange 33 over the slotted openings 34 in a known manner. It will be understood thatFlG. 4 consists essentially of an illustrationof the portions of such ceiling struts S and frame members F as are provided with air-handling facilities, and would in the majority of cases, correspond to the same location as the section shown in FIG. 2, that is to say, along opposite sides of the lighting fixture L. The sections of the end ceiling strut members and of the corresponding frame members would of course be essentially the same as shown in FIG. 4 without the air handling slots 34.

A still further embodiment of the invention is shown in FIG. 5 in which the use of the

horizontal flange

13 or 33 is dispensed with along two sides of the fixture. Again the position of the section of FIG. 5 corresponds essentially to the position of the section of FIG. 2 that is to say, along one of the two opposite sides of the lighting fixture L. In this embodiment, the ceiling strut S consists of the sidewall member 50 having a tile-supporting flange 51 and provided along its upper edge 52 with holes, (not shown) or other suitable supporting means for attachment of the supporting rods or wires R. An inwardly directed sealing flange 53 is provided near the upper end of the sidewall 54 to locate the boot B in position, and to make a seal therewith.

The inner frame member F shownin FIG. 5 is of similar construction to the ceiling strut S, and is provided with a sidewall 54 having a lower air deflector baffle member 55. The lighting fixture L is attached to upper edge 56 of frame member F by means of screws 57 and a sealing flange 58 is provided for sealing with the inner side of the boot B, a supporting flange 59 being provided for supporting a plastic panel P of the lighting fixture L. In this embodiment, there is no direct connection between the ceiling strut S and the frame member F along either of the two sides of the lighting fixture L. Thus the sealing

flanges

53 and 58, between them define a continuous air-handling opening indicated as 60 thereby providing for maximum free flow of air therethrough. It will be understood, however, that the ceiling struts S and frame members F at the two ends of the lighting fixture L must necessarily incorporate a flange member extending between them in order to provide support for the frame member F and accurately to locate the lighting fixture between the ceiling struts S. Thus, as shown in FIG. 6, the ceiling strut S at each end of the lighting fixture L is essentially the same as the strut S along each side of the lighting fixture L, and is referenced as 50A. Such an end strut 50A is provided with a support flange 61 adapted to underlie the sealing flange 58 on the frame member F the end of the lighting fixture. It will be understood that, in this way, the entire lighting fixture L is completely supported at each end and is positively located with respect to the struts S.

It will thus be seen, that by the use of either of the embodiments of FIGS. 4 and 5, the airflow-handling channel around the lighting fixture is again provided by two entirely separate members, namely the struts S and the frame members F, the struts S being fixed permanently in the ceiling, and forming part thereof, and the frame members F being attached directly to the lighting fixture L.

The design of the boots and air duct is conventional and is omitted for the sake of clarity. In cases where return air ducts are not used, for example, it might, however, be necessary to incorporate light baffles to ensure that no light can pass downwardly into the

openings

14, 34 or 60, since these are intended to be totally black and devoid of illumination at all times.

The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only.

What] claim is:

1. An air-handling ceiling channel system for use in association with a ceiling having a lighting fixture of the type including a housing having side and end walls, mounted in an opening-of corresponding shape in said ceiling, said channel system including a channel defined by pairs of spaced-apart and complementary separable wall members constituting respective inner and outer sidewalls of said channel, one of said wall members in each said pair being an integral part of the ceiling and attached around said opening and the other being attached to an adjacent portion of said lighting fixture and being removable therewith, and said air channel system being adapted to be connected at predetermined locations to airhandling ducting as outlet or return openings therefor, and said system comprising:

a plurality of ceiling strut members of predetermined height adapted to be built into said ceiling as an integral part thereof around said lighting fixture opening with theinner faces of said strut membersexposed and forming the outer wall surface of said channel, the outer faces of said strut members being juxtaposed with adjacent portions of said ceiling;

attachment means on said strut members for fastening them in position in said ceiling as an integral part thereof;

a plurality of lighting fixture frame members of predetermined height forming a continuous frame around said side and end walls of said lighting fixture housing, said frame members being fastened in position on said housing side and end walls as an integral part of said lighting fixture, and being movable therewith relative to said ceiling strut members;

outer and inner side surfaces on said frame members, said outer side surfaces being complementary with said exposed inner faces of said ceiling strut members around a said opening to form the opposite wall surfaces of a said channel when said lighting fixture is in position in a said opening; and

cooperating locating means on at least some of said strut members and on at least some of said frame members and extending therebetween to locate said strut members and said frame members in predetermined spaced complementary relation to form a continuous channel all around said lighting fixture, with air-handling openings at predetermined spaced locations, said frame members being removable from said location adjacent said strut members upon removal of said lighting fixture from said opening, without disturbing said locating means on said strut members.

2. The air-handling ceiling channel system as claimed in claim 1, wherein said lighting fixture incorporates a lens, and in which lens-supporting flange members are provided on said inner side surfacesof said lighting fixture frame members.

3. The air-handling ceiling channel system as claimed in claim 1, including ceiling support flange means formed on said ceiling strut members, and extending from the outer faces thereof for interengagement with adjacent portions of the ceiling.

4. The air-handling ceiling channel system as claimed in claim 1, in which said cooperating locating means comprise sealing flange means extending along said outer side surfaces of said lighting fixture frame members, in a predetermined plane, and sealing surface meansdefined by said locating means on said strut members, and engageable by said flange means when said strut members and said frame members are located in predetermined spaced relation.

5. The air-handling ceiling channel system as claimed in claim I, wherein said locating means on said strut members extend substantially across the full width of said channel into engagement with said locating means on said frame members, and include longitudinal slotted air passageways fonned therethrough for registration with said air handling ducting, when the same is located in position thereagainst.

6. The air-handling ceiling channel system as claimed in claim 1, for use with a lighting fixture having side and end walls and in a ceiling including a lighting fixture opening of a corresponding shape, in which said'ceiling strut members and said lighting fixture frame members together define and form a continuous recessed channel all around said lighting fixture, and wherein said air-handling openings are located only between the ceiling strut members and lighting fixture frame members along the sides of said lighting fixture opening and said lighting fixture.

7. The air-handling ceiling channel system as claimed in claim 6, wherein said ceiling strut members include ceiling strut members and ceiling strut end members for use along

Claims

1. An air-handling ceiling channel system for use in association with a ceiling having a lighting fixture of the type including a housing having side and end walls, mounted in an opening of corresponding shape in said ceiling, said channel system including a channel defined by pairs of spaced-apart and complementary separable wall members constituting respective inner and outer sidewalls of said channel, one of said wall members in each said pair being an integral part of the ceiling and attached around said opening and the other being attached to an adjacent portion of said lighting fixture and being removable therewith, and said air channel system being adapted to be connected at predetermined locations to air-handling ducting as outlet or return openings therefor, and said system comprising: a plurality of ceiling strut members of predetermined height adapted to be built into said ceiling as an integral part thereof around said lighting fixture opening with the inner faces of said strut members exposed and forming the outer wall surface of said channel, the outer faces of said strut members being juxtaposed with adjacent portiOns of said ceiling; attachment means on said strut members for fastening them in position in said ceiling as an integral part thereof; a plurality of lighting fixture frame members of predetermined height forming a continuous frame around said side and end walls of said lighting fixture housing, said frame members being fastened in position on said housing side and end walls as an integral part of said lighting fixture, and being movable therewith relative to said ceiling strut members; outer and inner side surfaces on said frame members, said outer side surfaces being complementary with said exposed inner faces of said ceiling strut members around a said opening to form the opposite wall surfaces of a said channel when said lighting fixture is in position in a said opening; and cooperating locating means on at least some of said strut members and on at least some of said frame members and extending therebetween to locate said strut members and said frame members in predetermined spaced complementary relation to form a continuous channel all around said lighting fixture, with air-handling openings at predetermined spaced locations, said frame members being removable from said location adjacent said strut members upon removal of said lighting fixture from said opening, without disturbing said locating means on said strut members.

2. The air-handling ceiling channel system as claimed in claim 1, wherein said lighting fixture incorporates a lens, and in which lens-supporting flange members are provided on said inner side surfaces of said lighting fixture frame members.

4. The air-handling ceiling channel system as claimed in claim 1, in which said cooperating locating means comprise sealing flange means extending along said outer side surfaces of said lighting fixture frame members, in a predetermined plane, and sealing surface means defined by said locating means on said strut members, and engageable by said flange means when said strut members and said frame members are located in predetermined spaced relation.

5. The air-handling ceiling channel system as claimed in claim 1, wherein said locating means on said strut members extend substantially across the full width of said channel into engagement with said locating means on said frame members, and include longitudinal slotted air passageways formed therethrough for registration with said air handling ducting, when the same is located in position thereagainst.

6. The air-handling ceiling channel system as claimed in claim 1, for use with a lighting fixture having side and end walls and in a ceiling including a lighting fixture opening of a corresponding shape, in which said ceiling strut members and said lighting fixture frame members together define and form a continuous recessed channel all around said lighting fixture, and wherein said air-handling openings are located only between the ceiling strut members and lighting fixture frame members along the sides of said lighting fixture opening and said lighting fixture.

7. The air-handling ceiling channel system as claimed in claim 6, wherein said ceiling strut members include ceiling strut members and ceiling strut end members for use along said sides and ends of said lighting fixture opening respectively, and wherein said locating means are provided only on said ceiling strut end members and on opposed lighting fixture frame members, said ceiling strut side members being free of any contact with their opposed lighting fixture frame members, whereby to define a continuous lengthwise air-handling opening therebetween, along the full length of each side of said lighting fixture.