Hanger assembly

A heavy duty expansible junction box hanger assembly adapted for installation from beneath a ceiling through a junction-box aperture in the ceiling without complete prior removal of a previously installed light-weight hanger assembly. The portion of the light-weight hanger directly above the aperture is cut away, and the heavy duty hanger is maneuvered through the aperture to a position above the light-weight hanger. A pair of feet on each end of the heavy duty hanger straddle the light-weight hanger and rest on the upper ceiling surface, aligning the heavy duty hanger parallel to the ceiling, after which joist engagement means on the hanger assembly are expanded into biting contact with the joists.

The invention relates to the art of hanger assemblies for suspending heavy 
objects such as ceiling fans, and more particularly to such assemblies 
which are adapted for installation through a junction-box aperture in a 
ceiling without complete prior removal of a previously installed 
light-weight hanger assembly, and without the necessity for entry into the 
attic. 
Numerous hanger assembly designs are known for installation of 
comparatively light chandeliers, light fixtures, or the like. These 
typically are installed from above the ceiling during construction of the 
building, and are quite satisfactory under these conditions. They are 
however not sufficiently rigid and sturdy to support a considerably 
heavier load, particularly a load which exerts torque and vibrations, such 
as a ceiling fan. 
The problem therefore arises of how to properly support such a heavier load 
when access to the space above the ceiling is not readily available. This 
problem is rendered more acute when a light-weight hanger assembly has 
been previously installed above the desired location, since removal of the 
light-weight assembly through an existing ceiling junction-box aperture 
would be quite difficult. 
These and other difficulties with prior art hanger assemblies are avoided 
by the present invention, as described below. 
According to a first major aspect of the invention, there is provided an 
expansible junction-box hanger assembly adapted for installation from 
beneath a ceiling through a junction-box aperture in the ceiling without 
complete prior removal of a previously installed light-weight hanger 
assembly, the expansible hanger assembly comprising first and second 
engagement means actuable for engaging and biting into respective first 
and second ceiling joists disposed above and on opposite sides of the 
aperture, the combination therewith of first and second alignment means 
for supporting the respective first and second engagement means 
independently of contact with the light-weight hanger assembly prior to 
actuation of the engagement means. According to another aspect of the 
invention, the alignment means comprises foot means for resting on the 
upper surface of the ceiling. According to another aspect of the 
invention, the alignment means comprises a pair of depending foot means 
for resting on the upper surface of the ceiling on opposite sides of the 
light-weight hanger assembly. According to another aspect of the 
invention, the expansible hanger assembly further comprises means defining 
a threaded bore extending along an axis from a first end toward a second 
end of a brace member; a rod having a first threaded end received within 
and mating with the bore and having a second end; means for mounting the 
first alignment means on the brace member for rotation about the axis 
relative to the brace member; and means for rigidly mounting the second 
alignment means on the rod. According to another aspect of the invention, 
the first engagement means is rigidly mounted on the first alignment 
means, and the second engagement means is rigidly mounted on the second 
alignment means. According to another aspect of the invention, the 
expansible hanger assembly further comprises means for expanding the 
assembly from a length of no greater than 141/2 inches to a length greater 
than 221/2 inches. 
According to a second major aspect of the invention, there is provided an 
expansible junction-box hanger assembly adapted for installation from 
beneath a ceiling through a junction-box aperture in the ceiling without 
prior complete removal of a previously installed light-weight hanger 
assembly, the expansible hanger assembly comprising an elongated brace 
member having first and second end portions, the brace member comprising 
means defining a bore extending along an axis from the first end portion 
toward the second end portion, at least a portion of the bore being 
threaded, and a non-round outer peripheral surface adapted for engagement 
by a wrench whereby the brace member may be rotated about the axis; a rod 
having a first threaded end received within and mating with the threaded 
portion of the bore and having a second end; first engagement means for 
engaging and biting into a first ceiling joist extending above and on a 
first side of the aperture; means for mounting the first engagement means 
on the second end of the brace member for rotation about the axis; second 
engagement means for engaging and biting into a second ceiling joist 
extending parallel to the first ceiling joist above and on the side of the 
aperture opposite the first side of the aperture; means for rigidly 
mounting the second engagement means on the second end of the rod; and 
alignment means for supporting the brace member and the rod substantially 
parallel to the plane of the ceiling and substantially perpendicular to 
the joists and above the light-weight hanger assembly. According to 
another aspect of the invention, the dimensions of the brace member, the 
bore, the rod, and the first and second engagement members are selected 
such that the expansible hanger assembly has an adjustable maximum 
dimension in a direction parallel to the axis at least as small as 141/2 
inches when the rod is fully received within the bore and greater than 
221/2 inches while the rod is still received within the bore. According to 
another aspect of the invention, the non-round peripheral surface 
comprises a plurality of planar portions extending substantially parallel 
to the axis over a region from 7.25 inches to 11.25 inches from the distal 
end of the first engagement means. According to another aspect of the 
invention, the expansible junction-box hanger further comprises clamp 
means for mounting a junction box having a substantially planar upper 
surface parallel to the axis and parallel to and in contact with one of 
the planar portions.

As shown in FIG. 1, the hanger assembly 18 of the invention is installed 
between parallel horizontal joists 20 and 22, the latter being broken away 
in the drawing in the vicinity of the hanger assembly for purposes of 
illustration. Ceiling 24 is supported by the lower surfaces of joists 20 
and 22, and is penetrated by junction-box aperture 26, the latter 
affording access from the room below. The center portion of a previously 
installed light-weight hanger assembly has been removed, as by sawing away 
with a hacksaw approximately even with the edges of aperture 26, leaving 
stub portions 28 installed. 
With reference to FIGS. 1 and 2, hanger assembly 18 comprises first and 
second engagement means 30 and 32 respectively, each of which is 
preferably in the form of a plurality of points for engaging and biting 
into the respective joists when actuated. Engagement means 30 are rigidly 
attached to alignment means 34 for supporting engagement means 30 
independently of contact with leftmost stub portion 28 as viewed in FIG. 
1, while engagement means 32 are rigidly attached to alignment means 36 
for supporting engagement means 32 independently of contact with rightmost 
stub portion 28 as viewed in FIG. 1. Each of alignment means 34 and 36 
preferably comprises a pair of depending feet 40 straddling the respective 
stub portions 28 and resting on the upper surface of ceiling 24 on 
opposite sides of the respective stub portions 28. 
Hanger assembly 18 further comprises elongated brace member 42 and rod 44, 
which together cooperate as means for actuating engagement means 30 and 
32. Brace member 42 has a bore 43 extending along an axis from its first 
end portion 46 toward its second end portion 48, the bore being internally 
threaded at end portion 46. The outer peripheral surface of brace member 
42 is nonround, the specifically preferred configuration being hexagonal 
(note FIG. 3). Rod 44 has a first threaded end 50 received within and 
mating with the threaded portion of bore 43. 
The second or opposite end of rod 44 is rigidly mounted on alignment means 
36, as by illustrated pin 52. Alignment means 34 is mounted for rotation 
about the axis of bore 43. As viewed in FIG. 2, a generally right 
circularly cylindrical protrusion 54 is rigidly attached to the right side 
of alignment means 34 and is received within the left end of bore 43. An 
annular groove 56 is formed on protrusion 54. Pin 58 is pressed through 
aperture 60 in the wall of brace 42 and protrudes into groove 56, thus 
preventing movement of alignment means 34 axially with respect to the axis 
of brace 42 while permitting relative rotation of brace 42 and alignment 
means 34 about the axis of bore 43. 
The preferred embodiment of the invention as thus described is installed as 
follows. With rod 44 rotated so as to be received within bore 43 to the 
maximum extent, the maximum dimension of the hanger assembly (measured 
from the tips of engagement means 30 to the tips of engagement means 32) 
is preferably at least as small as 141/2 inches, and most preferably at 
least as small as 141/4 inches. Hanger assembly 18 is maneuvered through 
aperture 26 until feet 40 on alignment means 34 straddle the leftmost stub 
portion 28 as viewed in FIG. 1 and rest on ceiling 24, while feet 40 on 
alignment means 36 straddle the rightmost stub portion 28 and also rest on 
ceiling 24. As thus arranged, alignment means 34 and 36 support brace 42 
and rod 44 substantially parallel to the plane of ceiling 24 and 
substantially perpendicular to joists 20 and 22, ready for axial expansion 
of engagement means 30 and 32 into biting contact with the joists. Brace 
42 is then rotated, as by engagement with a wrench, expanding engagement 
means 30 and 32 into biting contact with the joists, during which time the 
several feet 40 maintain brace 42 and rod 44 substantially parallel to the 
plane of ceiling 24. 
When the major components of hanger assembly 18 are tightly expanded 
between joists 20 and 22, rotation of brace 42 is stopped with one of the 
planar portions 60 of its outer periphery parallel to the plane of ceiling 
24 and the preferred remainder of the assembly (FIG. 3) is installed 
through aperture 26. Upper and lower brackets 62 and 64 have their opposed 
surfaces formed so as to be complementary to the non-round outer 
peripheral surface of brace 42, and are tightly secured to brace 42 by 
screws 66. Lower bracket 64 comprises a planar surface region 68 mating 
with surface 60 on brace 42, and a threaded neck 70 depending from lower 
surface 72, the latter being substantially coplanar with surface 68. Upper 
box portion 74 has an aperture 76 through its upper wall 78 for receiving 
neck 70, and has a planar upper surface 80. A locking nut 82 is screwed on 
neck 70 and tightened against lower surface 84 of wall 78, bringing upper 
surface 80 into contact with surfaces 68 and 60 for the full width of box 
portion 74 in the direction parallel to the axis of brace 42. This 
provides substantially increased rigidity of the assembly with minimum 
materials as compared to prior art designs wherein only a portion of the 
upper box surface contacts a bracing member. Finally, lower box portion 84 
is attached to upper box portion 74 by screws 86. The height of vertical 
side walls 88 of box portion 84 are selected in conjunction with the 
length of feet 40 so that the lower edge 90 of box portion 84 will be 
substantially flush with the lower surface of ceiling 26. Finally, 
recessed portions 92 are formed in opposed edges of the side walls of box 
portions 74 and 84, for introduction of wiring from the attic into the box 
prior to final installation of box portion 84.