Abstract:
An improved hanging apparatus with a locking swivel for suspending objects from an overhead structure is provided. The apparatus may advantageously be employed to suspend a heating, ventilation, and air conditioning (“HVAC”) unit from a ceiling, ceiling joists, beams, trusses, rafters, or the like of a room or space to be heated or cooled by the HVAC unit.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the priority benefit of U.S. Provisional Application Ser. No. 61/610,331 filed Mar. 13, 2012. The aforementioned provisional application is incorporated by reference in its entirety. 
     
    
     INCORPORATION BY REFERENCE 
       [0002]    This application is related to U.S. application Ser. No. 13/006,316 filed Jan. 13, 2011 and U.S. application Ser. No. 13/274,763 filed Oct.  17, 2011. Each of the aforementioned applications is incorporated herein by reference in its entirety.    
       BACKGROUND 
       [0003]    The present disclosure relates to improved systems and methods for hanging or suspending an object from an overhead structure. The present development will be described primarily by way of reference to a hanging apparatus for suspending a heating, ventilation, and air conditioning (“HVAC”) unit from a ceiling, ceiling joists, beams, trusses, rafters, or the like of a room or space to be heated or cooled by the HVAC unit, although it will be recognized that the apparatus herein could be adapted to hanging os suspending other objects. In certain embodiments, the system is adjustable to adjust the height at which the HVAC unit is suspended. In certain embodiments, a low profile hanger bar is employed, which may advantageously be employed in a finished space. In certain embodiments, the system is adjustable to accommodate HVAC units of different sizes. 
         [0004]    The present system is advantageously employed with an HVAC device that is connected to a fuel source by a pipe or flexible hose. Although the HVAC devices will typically be powered by natural gas or propane, it will be recognized that the present hanging system may be uses with all manner of heating and cooling units, including without limited to HVAC models that are powered by home heating oil, waste oil, diesel fuel, steam, hot water, and electricity. 
         [0005]    Commonly, suspended HVAC units are installed based on the orientation of the ceiling joists, beams, trusses, or rafters. Therefore, the direction of the heat or cold air is controlled only at the point of installation. Often, HVAC units are installed in a corner of a room and are only able to blow air straight ahead down the aligning wall, thereby reducing the heating or cooling efficiency of the HVAC unit. The present hanging system includes a locking swivel that allows the unit to be rotated in any desired direction. In this manner, the HVAC unit can readily be oriented to blow air out into the center of the room or area to be heated or cooled, thereby increasing the heating or cooling effectiveness of the unit installed. 
         [0006]    A traditional method of suspending an HVAC unit, illustrated in  FIG. 27 , employs the use of strut channels (e.g., UNISTRUT or the like) attached to the ceiling joists (or boards attached to or between the joists, as may be necessary to achieve a desired angular position of the HVAC unit) and threaded rods supporting the HVAC unit at its corners. When a non-swivel installation is completed, however, the HVAC unit is in a fixed position and cannot be adjusted unless it is reinstalled. This limitation can create extreme difficulty for the installer in that he may have to spend an inordinate amount of time calculating an acceptable path to best bring the fuel pipe, electrical and venting connections to this fixed position. In contrast, the present locking swivel system of this disclosure can be rotated to assist the installer with finding an optimal position for venting, fuel, and electrical connections. 
         [0007]    In addition to this flexibility during the installation phase for both the installer and the consumer (which does not exist for the prior art strut channel/threaded rod method), the present locking swivel system in accordance with this disclosure also provides additional advantages should the installed HVAC unit require routine maintenance or service down the road. For example, HVAC units typically have one or more removable access panels or doors that provide access to the interior of the unit for servicing or repair. In the prior art strut channel/threaded rod fixed installations, if an access panel is in an inconvenient location, such as adjacent to a wall or other obstacle, future servicing and repair of the HVAC unit can be made more difficult or time consuming. In the present system, however, the bolts on the locking swivel can be removed (and the fuel line shut off and disconnected, if applicable) to permit the HVAC unit to be rotated to a desired position that allows for easier and more effective access to the unit for the service required. In this manner, the installer is provided with the full range of installation options without compromising the future serviceability of the unit. Once the servicing or maintenance is completed, the HVAC unit can be rotated back to the desired position for operation and locked back into a fixed position once again. 
         [0008]    Although the present locking system will be described herein by way of reference to the preferred application of suspending an HVAC unit in a room, garage, basement, workshop, barn, warehouse, greenhouse, or other space to be heated or cooled, whether residential, commercial, or industrial, it will be recognized that the present system may be adapted to attach to all manner of overhead joists, beams, rafters, trusses, and other supports, whether of wood or metal (e.g., steel) construction. 
         [0009]    In addition to hanging air conditioning and heating units, the present locking system can readily be adapted to suspend virtually any type of equipment or items, including without limitation hay, tires, or equipment in a barn or large garage setting. In addition, the locking system may be made any size as dictated by the object to be suspended. For example, the size of the locking wheel system herein may be increased to allow it to be used for larger heating elements or larger objects. 
       SUMMARY 
       [0010]    In one aspect, an apparatus comprises an upper hanging member having at least one arm adapted to be attached at an upper end to an overhead structure and a horizontal portion attached to the at least one arm. A lower hanging member is adapted to attach to an object to be suspended from the overhead structure. An upper locking disk comprises a first planar body and a first pair of opposing walls projecting upward from the first planar body defining a first channel. The horizontal portion of the upper hanging member is received within the first channel. A lower locking disk comprises a second planar body and a second pair of opposing walls projecting downward from the second planar body defining a second channel. The lower hanging member is received within the second channel. A fastener extends through aligned bores in the horizontal portion of the upper hanging member, the first channel, the second channel, and the lower hanging member to provide a pivoting connection between the upper hanging member and the lower hanging member. A first plurality of spaced apart apertures is formed in the first planar body and arranged in a full or partial circular array. A second plurality of spaced apart apertures formed in the second planar body and arranged in a full or partial circular array. One or more fasteners are removably received in a selected one of the first plurality of spaced apart apertures and a selected, aligned one of the second plurality of spaced apart apertures for affixing the lower hanging member in a desired angular orientation relative to the upper hanging member. 
         [0011]    In another aspect, a kit having component parts capable of being arranged in a disassembled or partially disassembled form and of being assembled into a hanging swivel support apparatus is provided. The kit comprises an upper hanging member having at least one arm adapted to be attached at an upper end to an overhead structure and a horizontal portion attached to the at least one arm, and a lower hanging member adapted to attach to an object to be suspended from the overhead structure. An upper locking disk comprises a first planar body and a first pair of opposing walls projecting upward from the first planar body and defining a first channel. The horizontal portion of the upper hanging member is sized to be received within the first channel. A lower locking disk comprises a second planar body and a second pair of opposing walls projecting downward from the second planar body and defining a second channel, the lower hanging member being sized to be received within the second channel. A fastener is configure to extend through aligned bores in the horizontal portion of the upper hanging member, the first channel, the second channel, and the lower hanging member to provide a pivoting connection between the upper hanging member and the lower hanging member when the hanging swivel support apparatus is assembled. A first plurality of spaced apart apertures are formed in the first planar body and arranged in a full or partial circular array and a second plurality of spaced apart apertures are formed in the second planar body and arranged in a full or partial circular array. One or more fasteners are adapted to be removably received in a selected one of the first plurality of spaced apart apertures and a selected, aligned one of the second plurality of spaced apart apertures for affixing the lower hanging member in a desired angular orientation relative to the upper hanging member when the hanging swivel support apparatus is assembled. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention. 
           [0013]      FIG. 1  is a front elevational view of a first embodiment of the locking swivel hanger herein, wherein the hanger bars and the U-bar are in the fully retracted position. 
           [0014]      FIG. 2  is an enlarged perspective view of the region  2  appearing in  FIG. 1 . 
           [0015]      FIG. 3  is a front elevational view of the embodiment appearing in  FIG. 1 , wherein the hanger bars and the U-bar are in the fully extended position. 
           [0016]      FIG. 4  is a top view of the embodiment appearing in  FIG. 1  in the non-pivoted position. 
           [0017]      FIG. 5  is a top view of the embodiment appearing in  FIG. 1  in a pivoted position. 
           [0018]      FIG. 6  is an assembly view of the embodiment appearing in  FIG. 1 , wherein the hanger bars are shown in elevation view and wherein the swivel bar with the lower locking disk are shown in top plan view for ease of exposition. 
           [0019]      FIG. 7  is a photographic image of one of the locking wheels herein. 
           [0020]      FIG. 8  is an enlarged view of the locking wheel assembly in a partially rotated and locked position. 
           [0021]      FIG. 9  is a front elevational view of a second embodiment of the locking swivel hanger herein, wherein the hanger bars and the U-bar are in the fully retracted position. 
           [0022]      FIG. 10  is a front elevational view of the embodiment appearing in  FIG. 9 , wherein the hanger bars and the U-bar are in the fully extended position. 
           [0023]      FIG. 11  is a top view of the embodiment appearing in  FIG. 9  in the non-pivoted position, showing the swivel bar carrying the unit connector arms in the fully expanded position. 
           [0024]      FIG. 12  is a top view of the embodiment appearing in  FIG. 9  in the non-pivoted position, showing the swivel bar carrying the unit connector arms in the fully retracted position. 
           [0025]      FIG. 13  is a top view of the embodiment appearing in  FIG. 9  in a pivoted position, with the swivel bar carrying the unit connector arms in the fully retracted position. 
           [0026]      FIG. 14  is an assembly view of the embodiment appearing in  FIG. 9 , wherein the hanger bars are shown in elevation view, and wherein the swivel bar with the lower locking disk and the unit connector arms are shown in top plan view. 
           [0027]      FIG. 15  is a front elevational view of a third embodiment of the locking swivel hanger herein, illustrating the flush mount bar oriented perpendicular to the direction of the joists. 
           [0028]      FIG. 16  is a front elevational view of the embodiment appearing in  FIG. 15 , illustrating the flush mount bar oriented parallel to the direction of the joists. 
           [0029]      FIG. 17  is a top view of the embodiment appearing in  FIG. 15 , in the non-pivoted position. 
           [0030]      FIG. 18  is a top view of the embodiment appearing in  FIG. 15 , in a pivoted position. 
           [0031]      FIG. 19  is an assembly view of the embodiment appearing in  FIG. 15 , wherein the flush mount bar is shown in elevation view and wherein the swivel bar with the lower locking disk are shown in top plan view. 
           [0032]      FIG. 20  is a photographic image of an exemplary flush mount bar herein. 
           [0033]      FIG. 21  is a front elevational view of a fourth embodiment of the locking swivel hanger herein, illustrating the flush mount bar oriented parallel to the direction of the joists. 
           [0034]      FIG. 22  is a front elevational view of the embodiment appearing in  FIG. 21 , illustrating the flush mount bar oriented perpendicular to the direction of the joists. 
           [0035]      FIG. 23  is a top view of the embodiment appearing in  FIG. 21  in the non-pivoted position, showing the swivel bar carrying the unit connector arms in the fully retracted position. 
           [0036]      FIG. 24  is a top view of the embodiment appearing in  FIG. 21  in a pivoted position, with the swivel bar carrying the unit connector arms in the fully retracted position. 
           [0037]      FIG. 25  is a top view of the embodiment appearing in  FIG. 21  in the non-pivoted position, with the swivel bar carrying the unit connector arms in the fully extended position. 
           [0038]      FIG. 26  is an assembly view of the embodiment appearing in  FIG. 21 , wherein the flush mount bar is shown in elevation view, and wherein the swivel bar with the lower locking disk and the unit connector bars are shown in top plan view. 
           [0039]      FIG. 27  depicts the prior art method employing strut channels and threaded rods. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0040]    Referring now to the drawings, wherein like reference numerals denote like or analogous components throughout the several views,  FIGS. 1-5  illustrate a first embodiment locking swivel hanger unit  100 , which includes a generally U-shaped U-bar  102  having left and right vertically-extending (in the orientation shown in  FIG. 1 ) portions  104  and  106 , respectively, and a generally horizontal (in the orientation shown in  FIG. 1 ) portion  108  extending therebetween. The U-bar  102  is composed of square metal (preferably steel) tubing having a generally rectangular and preferably generally square cross-sectional shape and which is precut to size and fabricated to shape. 
         [0041]    Left and right hanger arms  114  and  116 , respectively, are telescopically received within the vertical portions  104  and  106 , respectively. The left and right hanger arms  114  and  116  are formed of square or rectangular tubing formed of steel or other metal having outer dimensions sized to be slidingly received within the vertical portions  104  and  106  of the U-bar  102 . The hanger arms  114 ,  116  have openings, e.g., drilled or punched openings  118 , spaced along their lengths, for example, located on centers which are between one and two inches for adjustability, although other spacings between the openings  118  are contemplated depending on the increment for adjustment. The vertical portions  104 ,  106  each have one or more (two in the illustrated preferred embodiment) openings  128  adapted to receive mechanical fasteners, such as screws, bolts, pins, clevis pins, etc. The hanger arms  114 ,  116  are telescopically adjusted relative to the vertical portions  104 ,  106  until the openings  128  align with desired ones of the openings  118  so as to provide for different height adjustments. 
         [0042]      FIG. 1  shows the hanger arms  114  and  116  in the fully retracted position and  FIG. 3  shows the hanger arms  114  and  116  in the fully extended position. In a preferred embodiment, the height of the U-bar and hanger arms may range from approximately 19.5 inches in the fully retracted position to about 27.5 inches in the fully extended position, although it will be recognized that the unit could be adapted for any desired height range. 
         [0043]    Although only the front surfaces of the hanger arms and the vertical portions appear in  FIG. 1 , the rearward facing surfaces will likewise have the spaced apart openings  118  and the one or more openings  128 . In preferred embodiments, either or both of the vertical portions and the hanger arms will also have spaced openings on the left and right facing surfaces. In an especially preferred embodiment, the hanger arms and the U-bar are formed of square tubing, wherein the vertical portions  104  and  106  each have openings  128  on the front and rear surfaces as well as the left and right surfaces. In this manner, it is only necessary for the hanger arms to have openings  118  on two parallel surfaces. 
         [0044]    In the illustrated embodiment of  FIG. 1 , wherein the hanger arms are inserted into the respective vertical portions such that the openings  118  are oriented from front to rear as illustrated, the hanger arms may be secured to a single joist (not shown) via fasteners (e.g., screws, bolts or other threaded or mechanical fasteners) passing through the openings  118 . Alternatively, the hanger arms can be removed from the vertical portions and rotated 90 degrees as indicated by the arrows, the hanger arms  114 ,  116  can be secured to parallel (e.g., adjacent) joists via fasteners passing through the openings  118 . In further embodiments, the hanger arms  104  and  106  may have spaced apart openings on all four sides allowing installation either parallel or perpendicular to the joists without the need to remove and rotate the hanger arms 90 degrees. 
         [0045]    A pair of locking plates, comprising an upper locking plate  130   a  and a lower locking plate  130   b,  is disposed between the transverse portion  108  and a transverse swivel bar  150 . The locking plates  130   a,    130   b  may be formed of a metal, e.g., steel, sheet or plate stock material. The swivel bar  150  may be made from the same tubular stock material as the U-bar  102 . 
         [0046]    As best seen in  FIG. 7 , an enlarged view of an exemplary locking plate  130  is illustrated. The plate includes a disc portion  132  and a pair of upstanding and facing vertical walls  134  defining a channel  136  therebetween. The walls  134  may be fabricated from a single piece of sheet or plate material and bending. The channel  136  of the upper plate  130   a  is sized to removably receive the U-bar transverse portion  108  and the channel  136  of the lower plate  130   b  is sized to removably receive the swivel bar  150 . In the illustrated embodiment, wherein the U-bar  102  and the swivel bar  150  are formed of the same type of tubular stock material, the upper and lower locking plates  130   a  and  130   b  may be of identical construction. 
         [0047]    The plate  130  includes a plurality of opening  138  in a generally circular array. A central opening  140  is provided for receiving a pivot fastener  142  (see  FIG. 8 ) such as pin, bolt, or the like. 
         [0048]    As best seen in  FIG. 8 , and with continued reference to  FIGS. 1-7 , the first plate  130   a  and second plate  130   b  are disposed back to back, with the transverse U-bar portion  108  being received within the channel  136  of the upper plate and the swivel bar  150  being received within the channel  136  of the lower plate. The pivot fastener  142  extends through the openings  140  in the plates  130   a,    130   b,  as well as through aligned openings in the transverse portion  108  and the swivel bar  150 . In this manner, the U-bar  102  and the upper plate  130   a  are rotatable relative to the swivel bar  150  and the lower plate  130   b.  In the illustrated embodiment, the pivot fastener  142  is a threaded bolt. In the depicted preferred embodiment, a threaded nut  144  is received on the threaded end of the bolt  142 . In the preferred embodiment, a removable pin  146 , which may be a cotter pin, R-clip, or the like, is received through a transverse bore in the end of the bolt  142  to prevent inadvertent removal of the nut  144 . In operation, the swivel bar  150  may then be rotated to any desired angular position A (see  FIG. 5 ) relative to the U-bar  102 . Preferably, a sufficient number of openings are provided to allow locking the swivel bar  150  at selected increments throughout  360  degrees of rotation. When the swivel bar  150  has been rotated to the desired position, one or more (preferably two) fasteners  148  are passed through vertically aligned openings  138  on the upper and lower plates  130   a,    130   b  to secure the U-bar and the swivel bar in the desired rotational position. In the depicted embodiment, the fastener is a threaded bolt  148  secured via a complimentary threaded nut  149 , although other mechanical fasteners, such as pins, clamps and so forth are also contemplated. 
         [0049]    In the depicted embodiment, the swivel bar  150  is illustrated as being formed of generally tubular stock having a generally square cross-sectional shape and having a plurality of openings  152  there for receiving fasteners used to secure an HVAC unit or other item or device to the swivel bar  150 . In the depicted embodiment, the openings  152  are elongated to allow adjustability, as will be described in greater detail below. It will be recognized that the swivel bar  150  may be adapted for the particular units or items to be suspended. 
         [0050]    Referring now to  FIGS. 9-14 , there appears a second embodiment locking swivel hanger  200  which adds H-bar bracket members  160  for suspending an HVAC unit or other item at four points, such as  4  points at or near the corners, but otherwise, the apparatus  200  is as described above by way of reference to the apparatus  100 . Unless stated otherwise, reference numerals appearing in  FIGS. 9-14  are as described above by way of reference to  FIGS. 1-8 , which discussion above is equally applicable and incorporated here by reference. 
         [0051]    The unit  200  includes the U-bar  102 , telescoping hanger arms  114  and  116 , wherein the swivel bar  150  and the upper and lower locking plates  130   a  and  130   b  are pivotally secured to the U-bar transverse section  108  as detailed above. Again, the hanger arms  114  and  116  are telescoping to allow the HVAC or other item to be suspended at a user-adjustable height between the fully retracted position (see  FIG. 9 ) and the fully extended position (see  FIG. 10 ). In addition, the swivel bar  150  may be pivoted to any desired angle A (see  FIG. 13 ) as described above. 
         [0052]    As best seen in  FIGS. 11 and 12 , the H-bars  160  are secured on opposite sides of the swivel bar  150  using a mechanical fastener (e.g., a threaded fastener)  154 . The H-bars  160  may be formed of a metal (e.g., steel) tubular stock material and may be, for example, formed of the same stock material as the U-bar and/or the swivel bar. The H-bars  160  each preferably include a plurality of openings  162  along its length. The H-bars  160  are secured via the fasteners  154  passing through one of the openings  152  in the swivel bar  150  and one of the openings  162  in the H-bars  160 , preferably a centrally located one of the openings  162 . In the depiction of  FIG. 11 , the H-bars  160  are secured when the fasteners  154  pass through the outer ends of outermost elongate openings  152  in the swivel bar  150 , thus illustrating the H-bar assembly in the fully extended position. 
         [0053]    Similarly, in the depiction of  FIG. 12 , the H-bars  160  are secured when the fasteners  154  pass through the inner ends of the innermost elongate openings  152  in the swivel bar  150 , thus illustrating the H-bar assembly in the fully refracted position. The exemplary dimensions for the fully retracted and expanded positions appear in  FIGS. 23  (13⅞ inches) and  25  (20¾ inches), respectively, discussed below and are equally applicable here, although other dimensions are contemplated. Intermediate positions may be obtained by loosening the fasteners  154  and positioning the H-bars  160  at intermediate positions within the elongate openings  152 , thereby accommodating HVAC units or other items of various sizes. 
         [0054]    The plurality of openings  162  are spaced along the length of the H-bars  160  and may be used to secure the HVAC unit or other item at four points, e.g., via mechanical fasteners passing through selected ones of the openings  162  and respectively aligned mounting hardware or brackets on the HVAC unit or other device to be mounted. The spacing of the openings  162  may be selected in accordance with common or conventional sizes of HVAC units to be supported and/or mounting hardware therefore. 
         [0055]    Referring now to  FIGS. 15-20 , there appears a third locking swivel embodiment  300  including the locking swivel assembly  130   a,    130   b  and swivel bar  150  as detailed above, but wherein the telescoping U-bar assembly is replaced with a low profile mounting bar  170 , which is advantageous for suspending the HVAC unit or other item in a finished space, e.g., where a drywall or other finish layer  182  does not allow direct access to the overhead ceiling joists  180 . Unless stated otherwise, reference numerals appearing in  FIGS. 15-20  are as described above by way of reference to  FIGS. 1-14 , which discussion above is equally applicable and incorporated here by reference. 
         [0056]    The low profile bar  170  includes left and right mounting arms  176  for attachment to an overhead surface and an offset central portion  178  containing a central opening  177 . The bar  170  may be formed out of a tubular metal (e.g., steel) stock material and may be bent to provide any desired profile, preferably  5 - 6  inches although any desired height between the arms  176  and the central portion  178  is contemplated. 
         [0057]    The low profile bar  170  may be secured via fasteners passing through one or more of the openings in each of the arms  176  and into a joist, beam, or the like  180 . As shown in  FIG. 15 , the bar  170  may be oriented perpendicular to the joists  180  and the openings  172  may be spaced along the lengths of the arms  176  so as to accommodate standard or conventional joist spacings. In a preferred embodiment, the inner set of openings  172  may be spaced apart approximately 24 inches on center and the outer set of openings  172  may be spaced apart approximately 32 inches on center. In addition, the openings  172  are preferably elongated to accommodate a variety of joist spacings and increase adjustability and/or to accommodate variations or tolerances in the joist spacing for applications in which the bar  170  is mounted perpendicular to the joists as shown in  FIG. 15 . Exemplary dimensions for spacing of the openings  172  appear in  FIG. 23  and are equally applicable here, although other dimensions are contemplated. As shown in  FIG. 16 , the low profile bar  170  may also be secured in an orientation parallel to the joists  180  along a single joist. 
         [0058]    The central portion  178  of the low profile bar  170  is received in the channel  136  of the disc  130   a.  The channel  136  of the lower disc  130   b  receives the swivel bar  150 . A fastener  142  passes through the central opening  177  in the center section  178  of the bar  170 , through the central openings  140  in each of the discs  130   a  and  130   b,  and through the central opening in the swivel bar  150  to pivotally secure the bar  170  to the swivel bar  150 . As shown in  FIG. 18 , the swivel arm  150  may be pivoted relative to the low profile bar  170  to a desired angle A. 
         [0059]    Referring now to  FIGS. 22-26 , there is shown a fourth exemplary locking swivel mount embodiment  400 , which is as described above by way of reference to  FIGS. 15-20 , except where the swivel bar  150  appears with the left and right H-bars  160  as described above by way of reference to  FIGS. 9-14 . Unless stated otherwise, reference numerals appearing in  FIGS. 22-26  are as described above by way of reference to  FIGS. 1-21 , which discussion above is equally applicable and incorporated here by reference. Again, the H-bar assembly can be rotated to any desired angle A (see  FIG. 24 ) and locked in position via fasteners  148  as detailed above. Likewise, the width of H-bar assembly can be adjusted between the fully expanded width appearing in  FIG. 25  and the fully retracted width appearing in  FIG. 23 , as described above. 
         [0060]    The invention has been described with reference to the preferred embodiments. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the amended claims.