HANGER ASSEMBLY

Abstract: 17heavy duty expansible junction-box hanger assembly (18) adapted for installation from beneath a ceiling through a junction-box aperture (26) in the ceiling (24) without complete prior removal of a previously installed light-weight hanger assembly (28). The portion of the light-weight hanger (28) directly above the aperture (26) is cut away, and the heavy duty hanger (18) is maneuvered through the aperture (26) to a position above the light-weight hanger (28) and rest on the upper ceiling surface (24), after which joist engagement means (30, 32) on the hanger assembly (18) are expanded into biting contact with the joists (20, 22).

Description: HANGER ASSEMBLY SPECIFICATION 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 previ- . ously installed light-weight hanger assembly, and with¬ out 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 build¬ ing, 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 proper¬ ly 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 assemb- ly has been previously installed above the desired loca- OMPI tion, since removal of the light-weight assembly through an existing ceiling junction-box aperture would be quite difficul . 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 in¬ vention, 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 as¬ sembly comprising first and second engagement means actu- able 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 independent¬ ly 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 com¬ prises foot means for resting on the upper surface of the ceiling. According to another aspect of the inven¬ tion, the " alignment means comprises a pair of depend- ing 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 mount¬ ing 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 ex¬ pansible hanger assembly further comprises means for ex¬ panding the assembly from a length of no greater than 14 1/2 inches to a length greater than 22 "1/2 inches. According to a second major aspect of the in¬ vention, 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 as¬ sembly 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 en¬ gagement-means on the second end of the rod; and align- ment 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 mem¬ ber, the bore, the rod, and the first and second engage¬ ment members are selected such that the expansible hanger assembly has an adjustable maximum dimension in a di¬ rection parallel to the axis at least as small as 141/2 inches when the rod is fully received within the bore and greater than 22 1/2 inches while the rod is still . received within the bore. According to another aspect of the invention, the non-round peripheral surface com¬ prises a plurality of planar portions extending sub- stantially 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. Other aspects will in part appear hereinafter and will in part be apparent from the following detailed description taken in connection with the accompanying drawings, wherein: FIGURE 1 is a perspective view of the major components of the preferred hanger assembly of the in¬ vention installed, as viewed from above the ceiling; FIGURE 2 is a side elevation view of the FIGURE 1 assembly, partially in section and partially exploded; and FIGURE 3 is an exploded vertical sectional view, including those further elements constituting the complete preferred embodiment of the invention. As shown in FIGURE 1, the hanger assembly 18 of the invention is installed between parallel hori¬ zontal 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 pene- trated 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 approxi¬ mately even with the edges of aperture 26, leaving stub portions 28 installed. With reference to FIGURES 1 and 2, hanger assembly 18 comprises first and second engagement means 30 and 32 respectively, each of which is prefer¬ ably 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 indepen- ently of contact with leftmost stub portion 28 as viewed in FIGURE 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 FIGURE 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. OMPI 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 non- round, the specifically preferred configuration being hexagonal (note FIGURE 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 FIGURE 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 pro¬ trudes 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 14 1/2 inches, and most preferably at least as small as 14 1/4 inches. Hanger assembly 18 is maneuvered through aperture 26 until feet 40 on align- f ιm OMP ment means 34 straddle the leftmost stub portion 28 as viewed in FIGURE 1 and rest on ceiling 24, while feet 40 on alignment means 36 straddle the rightmost stub por¬ tion 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 ro- tated, as by engagement with a wrench, expanding en¬ gagement 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 (FIGURE 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 co- planar 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 OM y*>- ip 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 por- tion 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 8_4. C14P

Claims: What is claimed is: 1. In an expansible junction-box hanger as¬ sembly adapted for installation from beneath a ceiling through a junction-box aperture in said ceiling without complete prior removal of a previously installed light- weight hanger assembly, said 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 said aperture, the combination therewith of first and second alignment means for supporting said respective first and second engagement means independently of con¬ tact with said light-weight hanger assembly prior to actuation of said engagement means. 2. The expansible hanger assembly defined in claim 1, wherein said alignment means comprise foot means for resting on the upper surface of said ceiling. 3. The expansible hanger assembly defined in claim 2, wherein each said alignment means comprises a pair of depending foot means for resting on the upper surface of said ceiling on opposite sides of said light¬ weight hanger assembly. 4. The expansible hanger assembly defined in any of claims 1 and 2, and 3, further comprising: a. means defining a threaded bore extending along an axis from a first end toward a second end of a brace member; b. A rod having a first threaded end received within and mating with said bore and having a second end; c. means for mounting said first align¬ ment means on said brace member for rotation about said axis relative to said brace member; d. means for rigidly mounting said second alignment means on said rod. 5. The expansible hanger assembly defined in claim 1, wherein said first engagement means is rigidly mounted on said first alignment means, and wherein said second engagement means is rigidly mounted on said second alignment means. 6. The expansible hanger assembly defined in claim 1, further comprising means for expanding said assembly from a length of no greater than 14 1/2 inches to a length greater than 22 1/2 inches. OMPI 7. An expansible junction-box hanger assembly adapted for installation from beneath a ceiling through a junction-box aperture in said ceiling without prior complete removal of a previously installed light-weight hanger assembly, said expansible hanger assembly com¬ prising: a. an elongated brace member having first and second end portions, said brace member comprising: (1) means defining a bore extending along an axis from said first end portion toward said second end portion, at least a portion of said bore being threaded, and (2) a non-round outer peripheral surface adapted for engagement by a wrench whereby said brace member may be rotated about said axis; b. A rod having a first threaded end received within and mating with said threaded portion of said bore and having a second end; c. first engagement means for engaging and biting into a first ceiling joist extending above and on a first side of said aperture; d. means for mounting said first engage- ment means on said second end of said brace member for rotation about said axis; e. second engagement means for engaging and biting into a second ceiling joist extend¬ ing parallel to said first ceiling joist above and on the side of said aperture opposite said first side of said aperture; f. means for rigidly mounting said second engagement means on said second end of said rod; and g. alignment means for supporting said brace member and said rod substantially parallel to the plane of said ceiling and substantially perpendicular to said joists and above said light-weight hanger assembly. 8. The expansible junction-box hanger defined in claim 7, wherein the dimensions of said brace member, said bore, said rod, and said first and second engage¬ ment members being selected such that said expansible hanger assembly has an adjustable maximum dimension in a direction parallel to said axis at least as small as 14 1/2 inches when said rod is fully received within said bore and greater than 22 1/2 inches while said rod is still received within said bore. 9. The expansible junction-box hanger defined in claim 7, wherein said non-round peripheral surface comprises a plurality of planar portions extending sub¬ stantially parallel to said axis over a region from 7.25 inches to 11.25 inches from the distal end of said first engagement means. 10. The expansible junction-box hanger defined in claim 9, further comprising clamp means for mounting a junction box having a substantially planar upper surface parallel to said axis and parallel to and in contact with one of said planar portions. OMPI

Inventors: REIKER KENNETH H, REIKER, KENNETH, H.
Applicants: REIKER KENNETH H, REIKER, KENNETH, H.
Application year: 1983
Main classification: F16M13
IPC codes: E04B9, E04C3, F16M13, F21V21