Abstract:
Manufactured sections of a support collar which inter-engage to form the appearance of a continuous support collar and which are secured together and secured to ceiling joists form a support surface for a ceiling dome. Each of the collar sections include a grooved recess for receipt of a lighting element. End portions of the collar sections having inter-engaging male and female portions to secure the collar sections together and provide the appearance of the continuous support collar. The collar sections additionally have a weight displacement pan mounted on top of the dome to distribute weight forces of an attachment suspended from the dome.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a prefabricated modular system for providing interengaged support collar sections to support a peripheral edge of a modular ceiling insert. The invention eliminates the need for costly and time consuming on-site fabrication. 
       BACKGROUND OF THE INVENTION 
       [0002]    Fifty years ago, windows were made on-site and required excessive time and expertise to cut the glass, cut and place wood molding to secure the window pane, and then caulking and painting of the window. Now windows arrive at the job site either completely or partially assembled, ready for installation into a rough opening left by the framing contractor. Not only are windows now quicker and easier to install, but in short, they are much better; providing better insulation, tighter fitting tolerances, better materials which last longer and function more smoothly. 
         [0003]    Most, if not all of today&#39;s ceilings are custom fabricated on site. This is a very time consuming process, requiring on-site skilled labor and is very costly. Whether a ceiling is a tray ceiling, coffered ceiling or some other combination, the ceiling requires extensive effort and attention to detail. Dome ceilings are rarely utilized because of the skill required to produce symmetrical curves. 
         [0004]    One of the few exceptions to a labor intensive process is a suspended ceiling with inset tiles utilized primarily in commercial buildings in which a suspension system is installed followed by removable acoustical tiles, typically 2′×4′ or 2′×2′ in size. The advantages of installation are obvious and the benefits and ability to replace the tiles in the future for a different look are far superior to old style “on site” fabrication methods. 
       SUMMARY OF THE INVENTION 
       [0005]    Just as windows are now modular and are almost entirely prefabricated in design, it is an object of the present invention to produce ceilings that are quick and easy to install by unskilled labor, saving time and expense; providing a superior product at a reduced cost. 
         [0006]    It is envisioned that a family of ceiling products will be available, made in different sizes and scales in various industrial processes (example: plastic and/or composite roto-molding, structural foam/web molding, injection molding, blow molding, even wood, wood products, metal, glass, etc.), whose parts integrate together, thereby maximizing their use and flexibility with easy installation. This would help eliminate the need for costly and time consuming on-site fabrication. 
         [0007]    One such ceiling includes a dome approximately six feet round in diameter that is manufactured at various scaled sizes. The dome is round but other designs are acceptable which are hexagonal, octagonal, rectanglar, square, etc. 
         [0008]    The working or attic surface provides the necessary structural support, while the inner surface or show side of the dome can be modified in a variety of shapes and designs and textures to offer the consumer a multitude of choices for their homes. The dome can be painted by the consumer. However, the dome will be fabricated such that painting will not be necessary. It is designed to support a light or ceiling fixture such as a ceiling fan or chandelier, but may be equally attractive if nothing is placed from the highest central point. 
         [0009]    There is a built in provision for either a rope light or fiber optic light source, or multiple focal lights that are provided for eight foot and/or twelve foot support collars that shine or reflect up on the dome to provide an indirect lighting effect. A smooth dome or a scalloped dome are possible alternatives. A “tray version” is possible which resembles a dome but is “flat” across the top, thereby not requiring as much vertical attic space for placement. All of the elevated structures have an ability to stack or nest together to minimize space during shipping and each provides insulation to the homeowner. 
         [0010]    To coordinate support for a six foot dome, prefabricated support collars have an outer diameter of eight or twelve feet. Combined with a six foot dome or tray, the support collars make up a total ceiling package of either an eight foot dome/tray or a twelve foot dome/tray. The support collars are manufactured in different sizes and scales to match with various dome sizes. 
         [0011]    For example, a six foot dome reduced by 50% would produce a three foot diameter dome. If the support collars are equally reduced, they would produce a total package of a four foot dome/tray ceiling and a six foot dome/tray ceiling, adding flexibility to the number of rooms that could utilize this smaller size. 
         [0012]    An eight foot collar is formed in quadrants, meaning that it takes four parts to make a whole supporting collar, while a twelve foot diameter collar is manufactured in one-eighth sections. These collars overlap to form an integrally appearing product and attach to the ceiling joists which are reinforced prior to installation to support the weight of the modular ceiling insert. The various domes “sit” on the collars and are interchangeable. This allows for multiple uses of the same parts but achieves different decorative looks. 
         [0013]    The collars have integrated within them the ability to place rope or fiber optic lights and/or pinpoint halogen-type lights. 
         [0014]    Various lag bolts and washers are used to secure the collar sections to the ceiling joists and draw bolts with washers are used to pull the pieces of the collar together. Male and female portions at opposite ends of the collar portions interfit to lock adjacent collar portions together. In addition, various light kits are used including a rope light kit and a fiber optic rope light which will allow for different colors to be illuminated through the fiber and thereby reflect up against the dome. Pinpoint halogen lights are used which are inserted at an uppermost point where the collars overlap and give a different lighting effect with areas of direct lighting and areas of shadows. 
         [0015]    A weight displacement pan may be used which is a metal pan, approximately 20-24″ in diameter that sits on top of the dome in the center and is of sufficient thickness to support the weight of suspended light fixtures, chandeliers or ceiling fans and to distribute those weight forces away from the center of the dome, thereby enhancing the weight bearing capacity and longevity of the dome. The weight displacement pan may be flat or conform to the shape of the outer working surface of the dome. 
         [0016]    Accordingly, it is another object of the present invention to manufacture sections of a support collar which interengage to form the appearance of a continuous support collar and which are secured together and secured to ceiling joists to form a support surface for a ceiling dome 
         [0017]    It is another object of the present invention to manufacture sections of a support collar which inter-engage to form the appearance of a continuous support collar and which are secured together and secured to ceiling joists to form a support surface for a ceiling dome with each of the collar sections including a grooved recess for receipt of a lighting element. 
         [0018]    It is still yet another object of the present invention to manufacture sections of a support collar which inter-engage to form the appearance of a continuous support collar and which are secured together and secured to ceiling joists to form a support surface for a ceiling dome with each of the collar sections including a grooved recess for receipt of a lighting element and with end portions of the collar sections having inter-engaging male and female portions to secure the collar sections together and provide the appearance of the continuous support collar. 
         [0019]    It is still yet another object of the present invention to manufacture sections of a support collar which inter-engage to form the appearance of a continuous support collar and which are secured together and secured to ceiling joists to form a support surface for a ceiling dome with each of the collar sections including a grooved recess for receipt of a lighting element and with end portions of the collar sections having inter-engaging male and female portions to secure the collar sections together and provide the appearance of the continuous support collar and with a weight displacement pan mounted on top of the dome to distribute weight forces of an attachment suspended from the dome. 
         [0020]    These and other objects of the invention, as well as many of the intended advantages thereof, will become more readily apparent when reference is made to the following description taken in conjunction with the accompanying drawings. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    The following drawings illustrate examples of various components of the support collar for modular ceiling insert disclosed herein, and are for illustrative purposes only. Other embodiments that are substantially similar can use other components that have a different appearance. 
           [0022]      FIG. 1  is a perspective view of the reinforced ceiling supports for an interconnected support collar of the present invention and illustrating a modular ceiling insert mounted on the support collar and the optional use of a weight displacement pan. 
           [0023]      FIG. 2  is a plan view of a modular ceiling insert and its support collar extending into an attic space above a ceiling. 
           [0024]      FIG. 3  is a bottom view showing the appearance of a mounted modular ceiling insert supported by the support collar of the present invention with the ceiling structural supports located above the ceiling shown in dotted lines. 
           [0025]      FIG. 4  is a perspective view of a one-quarter section of a support collar embodying the principles of the present invention. 
           [0026]      FIG. 5  is a partial sectional view illustrating the mounting of the support collar to support joists of a ceiling structural support and having a modular ceiling insert resting on the support collar and including a light kit. 
           [0027]      FIG. 6  is a perspective view of an alternate embodiment of the reinforced ceiling supports for an interconnected support collar of the present invention and illustrating a modular ceiling insert mounted on the support collar. 
           [0028]      FIG. 7  is a plan view of a modular ceiling insert and its support collar extending into an attic space above a ceiling. 
           [0029]      FIG. 8  is a bottom view showing the appearance of a mounted modular ceiling insert supported by the support collar of the present invention with the ceiling structural supports located above the ceiling shown in dotted lines. 
           [0030]      FIG. 9  is a perspective view of a one-eighth section of a support collar embodying the principles of the present invention. 
           [0031]      FIG. 10  is a partial sectional view illustrating the mounting of the support collar to support joists of a ceiling structural support and having a modular ceiling insert resting on the support collar and including a light kit. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0032]    In describing a preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. 
         [0033]    With reference to the drawings, in general, and to  FIGS. 1-5 , in particular, a first example of a support collar for a modular ceiling insert embodying the teachings of the subject invention is generally designated as  20 . With reference to its orientation in  FIG. 1 , the upper side of a modular ceiling insert  22  is shown. The ceiling insert  22  projects above a ceiling  24  having a plurality of parallel extending joists  26   a ,  26   b ,  26   c ,  26   d ,  26   e ,  26   f ,  26   g ,  26   h ,  26   i ,  26   j ,  26   k . Further structural support is provided by assembled groups of parallel extending joists  28   a ,  28   b  which extend perpendicular to joists  26 . 
         [0034]    As shown in  FIG. 2 , a particular configuration of ceiling structural supports is defined by a plurality of joists forming an octagon configuration. The sides of the ceiling structural supports are formed by joists  30   a ,  30   b ,  30   c ,  30   d ,  30   e ,  30   f ,  30   g ,  30   h . Secured to the ceiling structural supports  30   a - 30   h  are four support collar sections  40  as shown in  FIG. 4 . 
         [0035]    Each support collar section  40  includes a curved support portion  42  for supporting a peripheral edge of a modular ceiling insert  22 . Opposed end edges  44 ,  46  cooperate with adjacent support collar sections to interconnect adjacent support collar sections together and thereby define an opening to be filled by the modular ceiling insert  22 . End portion  46  includes a support flange  48  and a projection  50  for inter-engaging and supporting end  44  of an adjacent support collar section with the projection  50  fitting into a corresponding recess  52  of end portion  44  of an adjacent support collar section. 
         [0036]    Each of the support collar sections  40  include three vertically extending flat engagement portions,  54 ,  56  and  58 . Portions  54  and  58  are half the width of portion  56  so that when an adjacent support collar section is engaged with the section  40  shown in  FIG. 4 , the section  58  of the support collar section  40  and the section  54  of an adjacent support collar section will be equal in width to that of portion  56 . 
         [0037]    Therefore, as shown in  FIG. 2 , four support collar sections  40  are shown with four engagement-seam lines  60  separating adjacent sections  40 . However, due to the resting of end  52  on top of flange  48  of an adjacent support collar section, at least four flanges  48  will be seen when looking up from the floor to the ceiling assembly of support collar sections and modular ceiling insert as shown in  FIG. 3 . The flange portions  62  located between the flange portions  48  in  FIG. 3  are for decorative purposes only and need not be present. 
         [0038]    Each support collar section  40  includes a peripheral groove  66  for support of a rope like kit or a fiber optic rope  68 . The illumination from groove  66  provides illumination of the underside  70  of the modular ceiling insert  22 . 
         [0039]    As shown in  FIG. 4 , the support collar section  40  is secured in place to ceiling structural supports  30   a - 30   k  by lag bolts  72  extending through openings  74  in the vertically extending flat engagement portions so as to inter-engage and secure the support collar sections to the ceiling structural supports. In addition, draw bolts  76  are used to extend through lateral openings  78  in the ends  44 ,  46  of the collar sections  40  and be engaged by nuts  80  to draw together and secure adjacent support collar sections together. 
         [0040]    Depending upon an amount of attic space located above the ceiling  24 , the support collar section  40 , having a width of one foot, can be used in an eight foot opening to support a six foot diameter modular ceiling insert. Alternatively, as shown in  FIGS. 6-10 , a twelve foot opening can be used with eight support collar sections  100 , as shown in  FIG. 9 , each having a width of three feet, to support a six foot diameter modular ceiling insert  102 . 
         [0041]    With the support collar section shown in  FIG. 9 , a more elaborate ceiling structural support must be provided as shown in  FIGS. 6 and 7 . The support collar section  100  includes two levels of vertically extending flat engagement portions  102 ,  104  at one level, and  106 ,  108  at an upper level. An octagonal shaped series of ceiling structural supports as shown in  FIG. 6  for the lower engagement portions  102  and  104  and an upper series of ceiling structural supports  110 ,  112 ,  114  and  116  forming a square are provided to engage every other set of engagement portions  106 ,  108  of interconnected support collar sections  100 . Diagonally extending supports  118 ,  120 ,  122 ,  124  engage the remainder of the upper level of engagement portions of the support collar section  100 . 
         [0042]    To complete the support collar for the modular ceiling insert  102  shown in  FIGS. 6 and 7 , a series of eight support collar sections  100  are required to be interconnected. As was explained with reference to  FIGS. 4 and 5 , a plurality of lag bolts  130  extend through openings  132  in the collar section to engage with the joists and constructed structural supports located above the ceiling  136 . Also, draw bolts  134  are passed through openings  136  into adjacent collar sections  100  for engagement with nuts  138  to draw together and secure adjacent collar sections together with inter-engaged edges being supported by and covered by eight flanges  140 . Flanges  140  have a projection for engaging with a recess  142  of an opposed edge of an adjacent support collar section. 
         [0043]    The lowermost edge  150  of the modular ceiling insert  102  is supported in a groove  152  of the support collar section  100 . A light rope or fiber optic kit  154  is supported in a recess  156  of the collar section. 
         [0044]    In the embodiment in  FIGS. 1-5  and the embodiment of  FIGS. 6-10 , a weight displacement pan  160  or  162  as shown in  FIG. 1  may be secured to the top of the modular ceiling insert. The pan  160  is flat and provides an anchoring strengthener for supporting an electrical or decorative fixture hanging through opening  164  in the top of the modular ceiling insert. Alternatively, the displacement pan  162  may be curved to the configuration of the upper surface of the modular ceiling insert. 
         [0045]    The foregoing description should be considered as illustrative only of the principles of the invention. Since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and, accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.