Abstract:
The invention provides a bracket and method of its use for adapting standard wall angle trim for use in sloped ceiling construction. The disclosed bracket arrangement can be used for the top edge or bottom edge of a sloped ceiling and be adjusted to match the angle of any practical ceiling slope. In disclosed embodiments, the bracket has the form of a rectangular flat steel sheet. The sheet has a hinge or bend line running lengthwise in its mid-area. The bend line is made by cutting the sheet intermittently along its length and thereby dividing the sheet into two sections. The cuts may be made, for example, by punching elongated slots along the bend line in a blank being formed into the bracket. Also punched into the bracket blank are a plurality of holes distributed lengthwise on marginal areas of the two sections of the blank.

Description:
This application claims the priority of U.S. Provisional Application No. 61/247,744, filed Oct. 1, 2009. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention relates to suspended ceiling construction and, in particular, to accessories for constructing sloped suspended ceilings. 
     PRIOR ART 
     Suspended ceilings are widely used in commercial buildings because of their versatility and economy. Ordinarily, these ceilings comprise a rectangular grid made up of parallel main tees and intersecting cross tees and panels or tiles assembled in the spaces between the tees. Where the ceilings meet the walls, the ends of the tees are typically supported by elongated wall angles. The wall angle, ordinarily of roll formed sheet metal, has a horizontal exposed leg or face typically with an appearance harmonious in scale with the faces of the tees. Besides supporting the tee ends, the horizontal leg serves to conceal them for a finished appearance. A wall angle is usually fixed to a wall with longitudinally spaced fasteners driven through its vertical leg. The vertical leg and fasteners are concealed from view when the ceiling panels are thereafter installed. 
     Sloped ceilings are used to obtain different architectural effects and can be used to improve day lighting and contribute to LEED® Credit EQ-8.1. Standardized suspended ceiling components can be used to construct a sloped ceiling. However, in a sloped ceiling, conventional mounting of standard wall angles can be aesthetically and/or functionally unacceptable with a sloped ceiling at the bottom and/or top of the ceiling. 
     SUMMARY OF THE INVENTION 
     The invention provides a bracket and method of its use for adapting standard wall angle trim for use in sloped ceiling construction. The disclosed bracket arrangement can be used for the top edge or bottom edge of a sloped ceiling and be adjusted to match the angle of any practical ceiling slope. In disclosed embodiments, the bracket has the form of a rectangular flat steel sheet. The sheet has a hinge or bend line running lengthwise in its mid-area. The bend line is made by cutting the sheet intermittently along its length and thereby dividing the sheet into two sections. The cuts may be made, for example, by punching elongated slots along the bend line in a blank being formed into the bracket. Also punched into the bracket blank are a plurality of holes distributed lengthwise on marginal areas of the two sections of the blank. 
     The weakened hinge or bend line allows the bracket to be bent into two planes, one that aligns with a wall and one that supports the wall angle with one leg in the desired ceiling slope plane. Where the bracket is to hold a wall angle at the bottom of a slope the bracket is bent through an angle corresponding to the slope angle; where the bracket is to hold the wall angle at the top of the slope, the bracket is bent through an angle equal to 180 degrees less the sloped angle. In all cases, the attachment of the bracket to the wall is hidden from sight in the completed ceiling. 
     Preferably, the sections of the sheet on opposite sides of the bend line are proportioned so that when the bracket is bent or folded nearly 180 degrees, the section to be fastened to the wall is sufficiently wide such that its fastening holes are unobstructed by the other section or adjacent leg of the wall angle. 
     One embodiment of the invention takes the form of a simple flat rectangular plate punched with the elongated slots to form the bend line and a series of small holes for screws, pop rivets, or other fasteners to secure the bracket to a wall angle and to a wall. In another embodiment, the bracket is again stamped into a rectangular metal sheet, but includes integrally formed features proportioned to securely grip the wall angle in either condition at up or down sloped ceiling edges. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a somewhat schematic fragmentary cross-sectional elevational view of a sloped ceiling illustrating an application of the invention; 
         FIG. 2  is a face view of a first embodiment of a wall angle bracket constructed in accordance with the invention; 
         FIG. 3  is a perspective view of the bracket used to support a wall angle at an edge of a ceiling from which it slopes upwardly; 
         FIG. 4  is a perspective view of the bracket used to support a wall angle at an edge of a ceiling from which it slopes downwardly; 
         FIG. 5  is a face view of a second embodiment of a wall angle bracket of the invention; 
         FIG. 6  is an edge view of the second embodiment of the bracket; 
         FIG. 7  is a perspective view of the second embodiment bracket used to support a wall angle at the edge of a ceiling from which it slopes upwardly; and 
         FIG. 8  is a perspective view of the second embodiment bracket used to support a wall angle at the edge of a ceiling from which it slopes downwardly. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In  FIG. 1 , there is shown a run of main tees  10  that with other parallel main tees below and above the plane of the drawing cooperate with intervening cross tees (not shown) to form a grid of a suspended ceiling  11  in a generally conventional manner. The tees have their ends  12  supported on wall angles  13 . Brackets  14  support the wall angles  13  at respective walls  16 . The illustrated slope of the ceiling is 15 degrees, but it will be understood that the slope can range, say between 10 degrees and 25 degrees or even somewhat less or greater than these limits. Where required, seismic clips, known in the industry, can be used to secure the ends  12  of the tees  10  to a wall angle  13 . 
     It is desirable that standard wall angles can be used in sloped ceiling installations so that custom fabrication of this ceiling component for the low and high edges of the ceiling is avoided. The brackets of the invention serve this purpose by supporting a standard wall angle at any angle corresponding to the slope. More specifically, the brackets support a wall angle so that its lower leg, designated  17 , is parallel to the plane of the sloped ceiling. 
     A standard wall angle has its sides or legs  17 ,  18  nominally ⅞″ in width and typically is supplied in 10′ or 12′ lengths (or metric equivalent). Main tees  10  are typically nominally 1-½″ tall and it is desirable that such a dimension of the tees is accommodated at the perimeter of the ceiling, particularly at its lower edge. 
     Referring in particular to  FIG. 2 , a first embodiment of the adjustable bracket  14  of the invention is shown. The bracket  14  is a sheet metal stamping, for example, 0.024″ hot dipped galvanized, HDG G60/G40 steel in a soft condition enabling it to be bent with a permanent set. The bracket  14  has a rectangular profile and a longitudinally extending bend line  21  formed by a series of elongated intermittent slots  22  cut through its thickness. Short lands or uncut areas  23  leave the bracket  14  with adequate bending strength. The bend line  21  is offset from the longitudinal center of the bracket profile leaving major and minor sections  24 ,  26 . Preferably, the width of the major section  24  is at least 1-½″. A series of longitudinally spaced holes  28  are punched in each section  24 ,  26  spaced from its respective longitudinal free edge. As will be understood from the description below, the holes  28  in both sections can be used to either secure the bracket  14  to a wall  16  or to a wall angle  13 . 
     The bracket  14  is manufactured in its illustrated flat condition. Usually at the site where a ceiling is to be erected, the bracket  14  is manually bent on the bend line  21  to permanently set the sections  24 ,  26  in planes that intersect one another at an angle related to the slope of the ceiling being constructed. A study of  FIGS. 3 and 4  reveals that the bend is equal to the slope angle when the bracket  14  is deployed at the ceiling edge that extends upwardly. Alternatively, the bracket is bent into an angle which is substantially equal to 180 degrees minus the slope angle when it is deployed at the ceiling edge that extends downwardly ( FIG. 4 ). In both cases, the precise angle depends on the angle of slope of the ceiling. The large bend angle at the down edge of the ceiling permits the bracket  14  to be positioned above the plane of the ceiling and therefore be mostly out of view. To minimize the view, the wall angle  13  can be mounted on the wall side of the bracket  14 . 
     The brackets  14  can be attached to the wall angle with self-drilling screws or pop rivets. Brackets should be placed on 2′ centers or less. Ordinarily, the brackets  14  can be attached to the wall angle before being attached to a wall. The fasteners can be assembled in the series of holes in the relevant section  26  or  24 . In the case where the bracket  14  is used for a down edge and the manufactured holes are used to fasten the wall angle and bracket together, the bracket is secured to the wall angle before the bracket is bent to the desired angle. 
     As shown in  FIG. 1 , the major section  24  of the bracket  14  is sufficiently wide to provide clearance for the upper end, designated  31  of a standard grid tee  10  where the grid tee end abuts the wall angle  13 . Additionally, as suggested in  FIG. 4 , the major section  24  is sufficiently wide and the holes  28  are spaced from the bend line  21  a distance at least as great as the width of the minor section  26  such that in the down edge of the ceiling application, the holes  28  are accessible to receive fasteners without obstruction by the minor section. 
     The minor section  26  has a width, measured from the bend line  21 , about equal to the width of a side or leg  18  of the wall angle  13  and preferably not greater than this dimension. 
     Referring now to  FIGS. 5-8 , there is shown a second embodiment of an adjustable bracket  40  for use with a sloped suspended ceiling. The bracket  40  is originally formed with a generally rectangular profile and is preferably stamped from mild steel sheet stock such as described above in connection with the bracket  14 . As most clearly shown in  FIG. 6 , the bracket  40  is generally planar except for integral features enabling it to be secured to the wall angle without separate fasteners and to stiffen it. A line of spaced elongated slots  41  cut out of the blank formed into the bracket  40  weaken the sheet to make a bend line  42 . The bend line  42  separates the bracket into major and minor sections  43 ,  44 . Holes  46  are punched in the sections  43 ,  44  adjacent their respective longitudinal free edges  47 ,  48  for purposes of attaching the bracket to a wall  16  or, optionally, a wall angle  13 . 
     Both sections  43 ,  44  include a pair of rectangular tabs  51 ,  52  stamped or cut out of surrounding areas of the body or blank of the bracket  40  at these respective sections. Each tab  51 ,  52  is formed so that it lies in a plane spaced from the plane of its respective section  43 ,  44 . The tabs  51 ,  52  remain attached to their respective sections  43 ,  44  with a web  53 ,  54  as shown in  FIG. 6 . 
     Associated with each tab  51  or  52  is a catch or hook  56  stamped into the body of the tab. The catches  56  include edges  57  that project above the plane of the surrounding material of the tab and ramp or cam surfaces  58  from the plane of the surrounding tab material to the edge  57 . 
     A stiffening rib  59  parallel to the longitudinal direction of the bracket  40  is stamped into each section  43 ,  44 . The ribs help keep the sections  43 ,  44  flat when the sections are bent relative to one another on the bend line  42 . 
     The bracket  40 , like the previously described bracket  14 , is permanently bent on the bend line  42  to suit the slope of the ceiling. As in the case of the earlier described bracket  14 , this can be done manually in the field, i.e. at the building construction site. 
     Referring to  FIG. 7 , for ceiling edges sloping up, the bracket  40  is bent through an angle equal to the slope. The major section  43  is secured to a wall angle  13  by inserting the upstanding leg  18  of the wall angle between the main part of the major section  43  and the tabs  51 . The catches  56 , due to the wedge-like shape of the ramp area  58  slide over and trap a hem  61  along the longitudinal edge of the wall angle leg  18  thereby effectively securing the bracket  40  to the wall angle. It should be noted that the bracket  40  can be shifted along the wall angle to adjust its position to match the wall construction. The bracket  40  can be locked in place on the wall angle by a screw in any one of the holes  46  associated with the major section  43 . 
     Like the bracket  14 , for ceiling edges that slope down, the bracket  40  is bent 180 degrees less the slope angle. The bracket  40  is secured to the wall angle by slipping the upper leg  18  of the wall angle between the tabs  52  and the main part of the minor section  44 . The catches  56  retain the bracket  40  on the wall angle  13  by snapping over and locking on the hem  61 . The major section  43  is secured to a wall with screws or other fasteners assembled through the holes  46 . Prior to assembly to the wall, the bracket  40  can be shifted lengthwise of the wall angle  13  while it is secured thereto by the catches  56 . 
     Brackets  14  or  40  can be mounted to the wall  16  somewhere between the main runners or tees  10  of the ceiling  11  to allow ease of assembly of seismic clips, shown in phantom at  20  in  FIG. 1 , on the ends of the main runners if required. Where the ceiling slope angle is relatively large and a gap exists between the wall angle  12  and the wall  16  at the down ceiling edge, with either bracket  14  or  40 , an additional wall angle can be attached against the wall in a normal manner to conceal the gap. This can be done first and the brackets  14  or  40  with the tilted wall angle can be installed on top of the first wall angle. 
     While the invention has been shown and described with respect to particular embodiments thereof, this is for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiments herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention.