Abstract:
An interlocking suspension support hanger for mounting strut members off of a vertical threaded rod includes a pair of support hanger having a rectangular support body with a pivoting pin hole and a fastening pin hole on the support body and a recess opening leading to a center thread configured to fit around the vertical threaded rod. Further, a process for utilizing the support hanger to suspend a strut rack assembly from the vertically threaded rod without passing the assembly over the ends of the rod or removing the existing strut rack is disclosed.

Description:
FIELD OF THE INVENTION 
   This invention relates to suspended strut members and supports therefore. More particularly, the present invention relates to a method and apparatus for suspending additional strut members from a threaded rod that already has other strut members suspended, without removing the existing strut members. 
   BACKGROUND OF THE INVENTION 
   In architectural settings, it is often necessary to improve architectural structures by adding, changing or removing certain portions. Such architectural improvements and additions are constantly being made in commercial and industrial settings. More specifically, in many commercial and industrial settings, changes need to be made in modular, steel, aluminum, and fiberglass reinforced plastic framing products and accessories suitable for electrical, industrial, construction and other applications without welding or performing other permanent changes. One of the common problems encountered in changing the modular form of the architectural construction is the removal or addition of horizontal members to the existing threaded rod assemblies. To effectively add or remove horizontal members to existing threaded rod assemblies, such procedure requires the whole assembly to be removed and a new assembly to be installed. Then, the original assembly will be reinstalled, which is very labor intensive, and adds a substantial cost to a work project. 
   A strut system is a system of horizontally placed channeled strut members suspended from the ceiling on a plurality of vertical threaded rods. The channel strut member has a plurality of holes through which the vertical rods are received as the strut member is raised to the proper elevation. A washer and a threaded nut are run up on the rod to engage the bottom of the strut member or the top of the strut member and support the strut member on the rod. Pipes or electrical cables are supported horizontally on these pipe rack strut members and run horizontally overhead throughout the building. 
   When architectural improvements, additions or removals require new pipe or electrical hookups, or rerouting, the suspended pipes or electrical cables must be removed or replaced, or new ones added. This procedure often requires expensive periods of shutdowns while the pipe racks are disassembled. In some cases, a second layer or intermediate pipe rack may be installed above the existing one to allow placement of the new pipe or cable before the old ones are removed. 
   For instance, to install an intermediate pipe rack above an existing one, it is necessary to remove the old strut members from the vertical threaded rod, or to take off the nut and lower the strut members. The intermediate strut member must then be forced over the existing pipe and cable which often requires bending or cutting an existing support rod to allow the intermediate strut member to fit on the rods above the pipe and cable. Then the old lower strut member must be put back into position. This threading procedure alone takes many hours. 
   One solution has been to provide a split nut device, which can be assembled onsite to support strut members. Various split nut configurations, although not utilized to support strut members, are known in the art. Specifically, there are several patents which disclose various split nut configurations. 
   For example, U.S. Pat. No. 663,208 to Wrensch discloses a pair of nut sections, each having a central threaded perforation, wherein the nut sections are hinged together at one side and joined together at other side by a screw. As can be seen, each nut section is not identical with the other. Further two different parts are required for the fastener and the hinge portions. 
   U.S. Pat. No. 4,132,146 to Uhlig discloses a swivel nut assembly formed from a pair of pivotally interconnected U-shaped disks, each disk forming a U-shaped recess. Two separate parts which are distinct from each other are required for the fastener and the hinge portions. 
   U.S. Pat. No. 4,901,958 to Kelso discloses an interlocking pipe rack assembly including two elongate separate strut members with a fastening means. However, the fastening means does not disclose any simple manufacturing part nor does it disclose an interchangeable hinge-fastening portion. 
   Thus, none of these references offer a simple to manufacture device which is easy to install on a threaded rod with existing strut members. Therefore, a need exists which overcomes all of the shortcomings of the prior art references known in the art. 
   SUMMARY OF THE INVENTION 
   The present invention provides for a hanger for supporting a strut to a threaded support rod extending through the strut. The hanger includes a pair of planar hanger portions, each hanger portion including an access opening extending from a side edge thereof and including an internally threaded portion for insertable accommodation of the threaded rod. The hanger portions are pivotally interconnected defining an open position for placement about the threaded rod and a closed position defining a threaded aperture for threadedly receiving the rod. The hanger portions in the closed position is rotatably movable along the rod for supporting engagement with the strut, and the hanger portions are identically shaped. 
   In addition, the present invention provides for a trapeze hanger which includes a pivot pin and a fastening pin. Each of the hanger portions includes a pin hole to allow the hanger portions to pivot against each other. Further, each of the hanger portions includes a second pin hole for fastening the hanger portions with each other at a clasped position around the threaded rod. The invention provides for a same pin profile to be used interchangeably as a fastener and a hinge for assembly. 
   Further, the present invention also provides for a method for supporting a strut having a threaded rod extending therethrough. The method includes providing a pair of pivotally connected planar hanger portions, each hanger portion including an access opening extending from a side edge to a threaded internal portion, pivoting the hanger portions about the threaded rod to place the hanger portions in threaded engagement with the rod, and rotating the pair of hanger portions into supporting engagement with the strut. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the following, the present invention will be described with reference to the figures of the drawings wherein: 
       FIG. 1  is a perspective view of a portion of a strut rack system utilizing an interlocking strut member and three trapeze hangers of a preferred apparatus embodiment in various positions along the steps of a preferred method embodiment in accordance with the present invention; 
       FIG. 2  is a perspective view of the trapeze hanger of the present invention as shown in  FIG. 1  in a closed position; 
       FIG. 3  is another perspective view of the trapeze hanger as shown in  FIG. 2  in an open position; 
       FIG. 4  is a perspective view of another preferred embodiment of the present invention; and 
       FIG. 5  is a perspective view of an installation step of the preferred embodiment of  FIG. 1  in accordance with the present invention. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   Although the following description describes the invention as being utilized particularly in suspended strut rack installations, it should be understood that the apparatus may be used in various other construction applications. 
   Referring to the drawings by numerals of reference, there is shown in  FIG. 1 , a preferred strut rack assembly  10  which utilizes a strut  12  and a trapeze hanger  14  of the present invention. The trapeze hanger  14 , as shown in  FIG. 1 , includes two rectangular body portions  18  and  20  which overlap one another and have thin profile disc-shaped portions. In  FIG. 1 , the uppermost trapeze hanger  14  is shown in an open configuration and the lower trapeze hanger  14  is shown in the closed position. 
     FIG. 2  shows the two body portions  18  and  20  of the trapeze hanger  14  in a closed position. As can be seen, the top body portion  18  and the bottom body portion  20  each has a thin planar rectangular profile shape with a perimetrical vertical side edge  20   a . Each of these rectangular body portions  18  and  20  include recessed apertures,  22  and  24  respectively, extending inwardly from the side edge  20   a . The recessed apertures  22  and  24  are specifically configured to insertably accommodate the diameter of the threaded rod  16  shown in  FIG. 1 . 
   The rectangular profile as shown in  FIG. 2 , provides for side edge  20   a  with surfaces which can buttress against other architectural devices. The rectangular profile also provides for upper surface which supports struts and other parts. This rectangular profile generally conforms to the cross-sectional shape of strut  12 . 
   Further, as can be seen more readily in  FIGS. 2 and 5 , each of the recessed apertures  22  and  24  has a wider expanse at its opening at side edge  20   a . The wider expanse gradually narrows to center threaded inner portions  26  and  28  to define a tapered guide section. Such wider access expanse of the apertures  22  and  24  easily accommodates the diameter of the threaded rod  16  and guides the threaded rod  16  to the center threaded inner portion  26  and  28  during an effortless clamping action. 
   In addition, the body portions  18  and  20  include pivot holes  30  and  30 ′ provided adjacent to an end corner of the rectangular body for accommodating a hinge pin  34 . Similarly, the body portions  18  and  20  also include fastening holes  32  and  32 ′, located at the opposite end corner for accommodating a pin-shaped fastener or a fastening pin  36 . The fastening pin  36  together with the pivotal pin  34  allow the hanger  14  to be moved between an open configuration and a closed configuration. Further, as shown in  FIG. 2 , the hinge pin  34  and the pin-shaped fastener  36  are identical and can be manufactured with same specification, thereby saving manufacturing cost. 
   It should be understood that other types of fasteners other than the pins may be used to secure the body portions  18  and  20  together. For example, a bolt may be inserted through holes provided in each body and a nut installed on one end. Further, a projection and a recess combination may be utilized as well. 
   As can be seen in  FIG. 5 , the body portions  18  and  20  are constructed in a non-coplanar manner to allow rotation of the body portions against each other in a complete 360 degree turn without obstructing one another. Such feature allows the installer to rotate the body portions easily in a non-latched position and latch it against the threaded rod  16  later during installation. Further, as  FIG. 5  shows, the installer can grab the trapeze hanger  14 , open, place next to a threaded rod, rotate, clamp, and fasten it to a closed position with only one hand at hard to reach places or tight spaces demanding hand dexterity. 
     FIG. 3  shows an open position of the preferred embodiment where the recess apertures  22  and  24  come together to clasp around the threaded rod  16  (not shown). Because of the open and closed position feature of the preferred split nut embodiment as shown in  FIGS. 2 and 3 , an installer can suspend a strut rack assembly from one or more vertically threaded rods without passing the assembly over the ends of the threaded rods so as to permit quick and easy installation and removal. This greatly reduces the time and labor required to assemble, install, disassemble, and modify a suspended existing strut rack system. 
   Also, as can be seen in  FIG. 3 , each of the rectangular body portions  18  and  20  is non-coplanar as mentioned above. As none of the vertical edges of the rectangular body portions  18  and  20  abuts against each other, the components are less likely to rust and corrode. When the trapeze hanger  14  must be removed or its position changed, such design makes it easier to remove the rectangular body portions  18  and  20 . 
   Also seen in  FIG. 3 , the rectangular body portions  18  and  20  are identical components which provide for manufacturing expediency. In essence, if the top body  18  was flipped over, the fastening hole  38  would be exactly at same position as the fastening hole position of the bottom body  20 . Further, the inner portions  26 ,  28  of each body portion includes threads which are identical at corresponding positions. 
   The trapeze hanger of the present invention may be assembled in the following manner. The trapeze hanger body portions  18  and  20  may be placed together and the hinge pin  34  is tapped into the pivot hole  30  through two stacked rectangular body portions  18  and  20 . The body portions  18  and  20  are then oriented and the fastening pin  36  is totally inserted in one body portion  18  to define a hinged pair of body portions  18  and  20  with fastening pin allowing the pivotal opening and closing of the trapeze hanger  18  around the threaded rod  16 . 
   The trapeze hangers, manufactured as described above, can be produced from metal, hardened plastic, or elastomer. Further, such trapeze hangers can be manufactured by different processes, extrusions, machining, or stamping or combinations of any previously described processes. It is contemplated that the hanger  14  may be plated for corrosion resistance. 
   Alternatively, the profile of the present invention can encompass any other shape such as a completely round profile as shown in  FIG. 4 . Specifically,  FIG. 4  shows a second embodiment of the trapeze hanger  50  of the present invention. In contrast to the previous embodiment, the second embodiment  50  includes a circular disc top  52  and a circular similarly shaped disc bottom  54 . Each of these discs  52  and  54 , includes a wider access expanse of the aperture,  56  and  58  respectively, that tapers to a center threaded inner portion,  60  and  60 ′ respectively (not shown) and accommodates the diameter of the threaded rod  16  (not shown) to the center threaded inner portion,  60 ,  60 ′ during an effortless clamping action. A pivot hole  64  and  64 ′ (not shown) is provided on the top surface of each disc  52 ,  54 , adjacent to its perimeter, to accommodate a hinge pin  68 . Correspondingly, a fastening hole  62  and  62 ′ (not shown) is provided on the top surface of each disc  52 ,  54 , adjacent to its perimeter, opposite the pivot hole positions, to accommodate a fastening pin  66 . Similar to the first embodiment described above, the second embodiment also shows that the hinge pin  68  and the fastening pin  66  as well as the discs  52  and  54  are identical. Additionally, the round trapeze hanger  50  as shown can have a “flat” portion not shown or other gripping features so that it can be rotated by a tool. The “flat” portion or any other gripping feature may be placed 180 degrees apart from each other. Alternatively, the present invention can also include a hexagon or an octagon profile or any other shape or profile as can be appreciated by a person skilled in the art. 
   Referring now to  FIGS. 1 and 5 , the trapeze hanger  14  is used to support a strut member  12  forming a suspended strut rack assembly  10 . The strut members  12  may have transverse slots formed when they are manufactured. Alternatively, the strut members may be without slots and the slots may be formed in the strut at the job site to correspond to the size and spacing of the existing threaded rods. 
   The strut member  12  has an inwardly rolled top edge which extends longitudinally the length of the strut. Any number of clamps, framing, or straps (not shown) may be interconnected to the rolled top edge to provide any different number of architectural configurations. 
   Installation 
   Having described the physical attributes of the trapeze hanger, a preferred installation method shall be described. As can be seen in  FIG. 1 , the trapeze hanger  14  is installed on a vertical threaded rod  16  at the appropriate location by opening the pair of body portions  18  and  20 . Then, the wide recess opening  22  of the rectangular metal body portions  18  is placed around the shaft of the threaded rod  16 . The installer then clasps the two body portions  18  and  20  together, thereby guiding the threaded rod  16  into the threaded inner member  26  and  28 . The installer then tightens the internal threaded portions around the shaft of the threaded rod. Once this is completed, the installer then installs the fastener pin into the fastening pin holes  32 ,  32 ′ to maintain the trapeze hanger in a threaded engagement as a single rotatable unit with the threaded rod  16 . The assembled trapeze hanger can then be moved up or down on the threaded rod  16  in the conventional manner to a desired position. The trapeze hanger may be received beneath the lower strut member  12  as shown in  FIG. 1  at level to support the strut member. 
   The trapeze hanger  14  may be turned by hand or with a wrench to adjust its height or the level of the assembled strut. The steps are then repeated to install additional strut assemblies on other threaded rods  16  to form a plurality of generally parallel spaced strut assemblies capable of receiving and supporting pipes, cables, and the like thereon. 
   When it becomes necessary to remove the pipe strut assembly, the trapeze hanger  14  can be quickly removed by unfastening the pin  36  and opening the body portions  18  and  20  of the trapeze hanger  14 , allowing the assembled strut to slide off the end of the threaded rods  16 . If there is an obstruction beneath the strut assembly, the bolts can be undone by allowing the strut members to be separated and removed laterally from the threaded rods  16 . 
   The above described apparatus and method provides a strut rack system which may be installed as original equipment to become the primary strut rack or may be easily and quickly installed as an intermediate or upper rack above existing strut racks without the necessity of removing any members already in place. 
   While this invention has been described fully and completely with special emphasis upon a preferred embodiment, it should be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.