Abstract:
The invention features an apparatus and method for positioning and supporting a sprinkler head in a ceiling, floor, or wall. In one aspect of the invention, a sprinkler head may be received by a sleeve extending through a broad surface of the plate. The plate may be configured to be removably attached to a support structure in the ceiling, floor, or wall and having an exterior surface exposed to the room or the plate may be attached to a decorative panel which is configured to be removably attached to a support structure in the ceiling, floor, or wall and having an exterior surface exposed to the room. The sleeve may be defined by an opening in the plate or it may be a separate structure permanently or removably attached to the plate.

Description:
TECHNICAL FIELD  
         [0001]    This invention relates to a fire protection sprinkler head support system.  
         BACKGROUND  
         [0002]    A typical automatic fire sprinkler system includes a network of pipes that carry a fire suppression fluid, e.g., water, to each room in the building. Conduit sections carry the fluid from the pipes to sprinkler heads strategically located in different rooms. The position and orientation of each sprinkler head is typically maintained in place by a support mechanism. When the room reaches an elevated temperature due to a fire, the sprinkler head is activated allowing a stream of fire suppression fluid to be directed over the intended area of coverage. During operation, the fluid pressure at each sprinkler head can reach significant levels of pressure (e.g., 175 psi), generating substantial back pressure on the sprinkler head&#39;s support system. The support mechanism must be capable of holding the sprinkler head securely in place during operation.  
           [0003]    Flexible fire protection sprinkler systems are described in U.S. Pat. No. 6,076,608 and U.S. Pat. No. 6,123,154, both of which are incoporated herein by reference.  
         SUMMARY  
         [0004]    The invention features an apparatus and method for positioning and supporting a sprinkler head in a ceiling, floor, or wall.  
           [0005]    According to one aspect of the invention, the invention features a panel attached to a hub. The hub includes a plate attached to the panel and a sleeve defining an opening extending through the broad surface of the plate. The sleeve is configured to receive the sprinkler head through the opening.  
           [0006]    In another aspect, the invention features a plate having an exterior surface exposed to the room and a sleeve defining an opening extending through the broad surface of the plate. The sleeve is configured to receive the sprinkler head through the opening.  
           [0007]    In yet another aspect, the invention features a plate attached to a decorative panel attached to the plate. The plate is configured to attach to the sprinkler head and the decorative panel includes an exterior surface exposed to the room and having a hole and configured to receive the sprinkler head therethrough.  
           [0008]    One or more of the following features may be included: The plate may have a hole configured to the receive the sprinkler head therethrough. The apparatus may also include a sleeve permanently or removably attached to the plate and defining an opening extending through the broad surface of the plate, the sleeve configured to receive the sprinkler head through the opening.  
           [0009]    The plate may be permanently or removably attached to the panel and may be attached to the panel with a fastener. The plate may also be laminated to the panel or at least partially integrated within the panel.  
           [0010]    The panel may have a length L and a width W and the plate has a length and width substantially equal to L and W, respectively. The plate may be in the shape of a ring having a thickness T and an inner diameter R 1  and an outer diameter R 2  and the sleeve is defined by the opening of the plate.  
           [0011]    The panel may have a certain rigidity characteristic and the plate may have a rigidity characteristic that is greater than the rigidity characteristic of the panel. The panel may be formed from PVC and the plate may be formed from stainless steel.  
           [0012]    The plate may have a hole extending through its broad surface and the sleeve may be defined by the hole in the plate. The sleeve may be a separate structure from the plate that is permanently or removably attached to the plate. The sleeve may be a telescoping sleeve which is configured to open to receive a sprinkler head and closed to secure the sprinkler head in plate. The plate may define a channel sized to slidably receive the sprinkler head. Additionally, the plate may include a plurality of sleeves, each of which are configured to receive a sprinkler head.  
           [0013]    The invention may also include one or more attachment members, each having a first end attached to the plate and a second end configured to engage the support structure in the ceiling, floor, or wall. The second end of the attachment members may include a foot to engage the support structure, the second end of the attachment members may also include a fastening device to attached to the support structure. One or more of the attachment member may be at least partially integrated within the decorative panel and angled relative to the plate. The attachment members may be in the form of legs.  
           [0014]    The plate may include a first and second plate section and the sleeve may include a first sleeve section attached to the first plate section, and the first plate section may be removably attached to second plate section.  
           [0015]    The invention may also include one or more brackets, each having a first and second surface. The first surface of each bracket may be permanently or removably attached to the plate and the second surface of each bracket may be permanently or removably attached to the panel.  
           [0016]    The invention may also include a flexible sprinkler assembly permanently or releasably attached to the sleeve. The flexible sprinkler assembly may include a flexible conduit, a fitting attached to the flexible conduit, and a sprinkler head attached to the fitting. The flexible sprinkler assembly may be attached to supply pipes. The sleeve may be integral to the sprinkler head and the height of the sprinkler head may be adjusted within the sleeve.  
           [0017]    The invention may also include a rod having a first end attached to the hub and a second end adapted to be attached to the ceiling, floor, or wall.  
           [0018]    The panel may be configured to be inserted into a plurality of support members forming a suspended ceiling.  
           [0019]    The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
       
    
    
     DESCRIPTION OF DRAWINGS  
       [0020]    [0020]FIG. 1 is a perspective view of two sprinkler support panels, positioned within a suspended ceiling.  
         [0021]    [0021]FIG. 2 is a perspective view of one of the sprinkler support panels of FIG. 1.  
         [0022]    [0022]FIG. 3 is a perspective view of a sprinkler support panel receiving a sprinkler head assembly.  
         [0023]    [0023]FIG. 4 is a side view of a sprinkler head.  
         [0024]    [0024]FIG. 5 is perspective view of a primary and auxiliary sprinkler head support system.  
         [0025]    [0025]FIG. 6 is a top view of another sprinkler support panel having four support legs.  
         [0026]    [0026]FIG. 7. is a perspective view of another sprinkler support panel having an integrated decorative panel and hub.  
         [0027]    [0027]FIGS. 8A and 8B are a side and top view, respectively, of another decorative support panel having a pair of support brackets.  
         [0028]    [0028]FIG. 9 is a top view of another sprinkler support panel having a sliding slot sleeve for receiving a sprinkler head.  
         [0029]    [0029]FIG. 10 is a perspective view of another sprinkler support panel having a split hub.  
         [0030]    [0030]FIG. 11 is a top view of another sprinkler support panel having a ring-shaped plate and four support legs. 
     
    
     DETAILED DESCRIPTION  
       [0031]    Referring to FIG. 1, a sprinkler system  2  includes two decorative support panels  10  mounted within a ceiling  4  having a ceiling frame  6  and an array of rectangular frame sections  8 . The array of rectangular frame sections  8  support the decorative support panels  10  as well as an array of decorative ceiling panels  11 .  
         [0032]    As will be described in greater detail below, each decorative support panel  10  includes a decorative panel  12  and a hub  14 . Hub  14  further includes a plate  16  and a sleeve  18  and is configured to receive a sprinkler head  42  (shown in FIG. 3). Decorative support panel  10  secures sprinkler head  42  at a predetermined position within one of the rectangular frame sections  8 . A flexible conduit  20  carries a fire suppression fluid, e.g., water, from supply pipes  22  to sprinkler head  42 . Pipes  22  can be part of a fluid delivery system dedicated to fire suppression or can also deliver water to other functions (e.g., a water faucet, toilet, dishwasher, etc.). When the room reaches elevated temperatures, sprinkler head  42  is activated and a stream of fire suppression fluid is directed into the room to extinguish the fire.  
         [0033]    In order to function effectively, sprinkler head  42  must be held firmly in place during operation. Due to the significant back pressure of the fluid flowing through the sprinkler head during operation, sprinkler head  42  is subjected to significant side, rotational, and torsional forces, which are capable of changing the position of the sprinkler head  42 , thereby causing the fluid to be directed away from the intended target. During operation, the decorative support panel  10  is configured to resist movement of sprinkler head  42  by distributing the forces to the four edges of decorative panel  12  which, in turn, are distributed to the ceiling frame  6 .  
         [0034]    The underside (i.e., the side exposed to the room) of decorative panel  12  may be designed to match adjacent decorative ceiling tiles  11  in order to present an aesthetically pleasing appearance in the room. Additionally, decorative panel  12  may be formed from materials commonly used to make standard decorative ceiling panels such as softboard, wood fiber composite, polymers, melamine foam, or fibrous plaster.  
         [0035]    Referring to FIG. 2, in a sprinkler system  2 , a length of flexible conduit  20  is located between a pipe  22  and a decorative support panel  10 . One end  20   a  of flexible conduit  20  is attached to pipe  22  by a fitting  32 . Fitting  32  can be any one or more commonly known methods of connecting to pipe, including, for example, threaded, grooved, socket welded, socket glued, regular welded, pressed fit, compression fitting, or a flare fitting connection. In addition, an adaptor (not shown) can be used to attach fitting  32  to flexible conduit  20 . The method selected for fitting  32  will depend on the material used for conduit  20  and the type of fire suppression fluid using in the sprinkler system. Fitting  32  can be made of any material, but the material will also generally depend on the material used for the conduit  20  and the type of fire suppression fluid used in sprinkler system  2 .  
         [0036]    A second end  20   b  of flexible conduit  20  is attached to a fitting  34  which is, in turn, attached to sprinkler head  42  (shown in FIG. 3) by any of the above methods. As with fitting  32 , the type of connection and the material used for fitting  34  can depend on the material used for conduit  20  and fire suppression fluid. Fitting  34  can be a rigid, substantially cylindrical tube such as a reducing fitting.  
         [0037]    Referring to FIG. 3, decorative support panel  10  includes a decorative panel  12  and a hub  14 . Hub  14  further includes a sleeve  18  and a plate  16 .  
         [0038]    Hub  14  is mounted to the decorative panel  12  such that it will remain attached to the decorative panel during operation in a high temperature environment. In FIG. 2, plate  16  is laminated to decorative panel  12 , however, it may be mounted to decorative panel  12  in a number of ways, including by glue, adhesive, cement, bolts, screws, or a combination of these. Additionally, the decorative panel  12  may be formed (e.g., by injection molding) partially or completely around the plate  16 .  
         [0039]    Hub  14  may be formed from any rigid material capable of withstanding high temperature environments likely to be experienced in a fire such as steel, steel alloy, iron, aluminum, titanium, copper, ceramic, ceramic composite, or high temperature plastic.  
         [0040]    Sleeve  18  of hub  14  is secured to plate  16   a  and is adapted to receive sprinkler head  32 . Sleeve  18  may be secured to plate  16  either permanently or removably using a number of commonly known methods including, for example, welds, glue, adhesive, cement, rivets, bolts, screws, clips, pins, a sliding slot (as illustrated in FIG. 9), or any combination of these. Additionally, sleeve  18  and plate  16  may formed of a single-piece construction by, for example, injection molding hub  14 .  
         [0041]    Sprinkler head  42  and fitting  34  form a sprinkler head assembly  44 . The sprinkler head assembly  44  fits into sleeve  18  and is removably secured by set screw  46 . Sprinkler head assembly  44  may also include a series of grooves on its outer surface to receive set screw  46  which would further secure sprinkler head assembly  44  within sleeve  18 . The inner diameter of sleeve  18  should be only slightly larger than the outer diameter of sprinkler head assembly  44  in order to reduce the ability of sprinkler head assembly  44  to move within sleeve  18  during operation. Using a set screw  46  allows the height of sprinkler head assembly  44  to be adjusted relative to the bottom surface of the decorative panel  12   b  while also functioning to secure sprinkler head assembly  44  in place. While the use of a set screw is illustrated in FIG. 3, many other commonly known methods may be used to removably secure sprinkler head assembly  44  within sleeve  18 , such as bolts, clips, pins, and the like. Additionally, sprinkler head  42  may be secured to sleeve  18  by configuring sleeve  18  as a telescoping sleeve. In this embodiment, the telescoping sleeve is rotated in one direction to open its center. While open, sprinkler head  42  is inserted and positioned to the proper height. Once sprinkler head  42  is in place telescoping sleeve is rotated in the opposite direction to close it and fasten sprinkler head  42  in place.  
         [0042]    Sprinkler head  42  can be any of the sprinkler head designs commonly used in the fire protection industry. For example, with reference to FIG. 4, sprinkler head  42  includes a length of cylindrical pipe  45  having a fluid passage obstructed by a plug  46 . Plug  46  is held in place by fusible links  47 , which are fabricated to melt within a specific temperature range, e.g., between 130° F. and 212° F.  
         [0043]    Alternative methods of holding plug  46  in place include a bottle of glycerin that expands when heated to break the vile. When links  47  break, plug  46  is released from pipe  45  by the pressure of the sprinkler system fluid, and the fluid is scattered over a wide area by a dispersion device  48 . The outer surface of pipe  45  includes threads  49  for connection to a fitting.  
         [0044]    In certain situations, a support structure, such as the suspended ceiling  4  shown in FIG. 1, can either fail, that is, fall down, or may be removed during renovations or repairs. For example, during a fire or an earthquake all or parts of ceiling frame  6  can collapse. Similarly, a crew removing ceiling frame  6  during renovations may not always take care to separate the sprinkler system from the decorative support panel  10  before it is torn down. In addition, if it is suspected that a fire is located above a suspended ceiling, a suspended ceiling may be torn down. Also, local codes may require that the sprinkler system continue to operate when the ceiling is torn down.  
         [0045]    In these situations, if the sprinkler heads are solely supported by a decorative support panel  10  inserted in a ceiling frame  6 , then the sprinkler head support system will likely fail when the ceiling frame  6  is torn down. This could result in significant damage to the sprinkler system as well as damage to building due to water leaks. Moreover, if, due to this damage, sprinkler system  2  fails to operate during a fire or an earthquake the building may be destroyed.  
         [0046]    A sprinkler system  2  will likely not be damaged or fail to operate if a support system includes an auxiliary support mechanism such as a rod, chain, wire, or rope attached to a building component.  
         [0047]    For example, as shown in FIG. 5, sprinkler system  2  can include a primary support system and an auxiliary support system  50 . Primary support system includes a decorative support panel  10   a.  Auxiliary support system  50  includes a rod  51  attached between the sleeve  18  and a building component  52 . Rod  51  is designed to perform two functions. First, rod  51  helps to hold sprinkler head  42  (not shown in FIG. 6) in place by resisting the back pressure and twisting forces generated during sprinkler head operation. Second, in the event of support structure failure, as described above, the sprinkler head  42  (and decorative support panel  10   a ) will hang from rod  51 , enabling sprinkler head  42  to remain in position and continue to provide fire protection.  
         [0048]    To provide these advantages, an upper portion  51   a  of rod  51  is connected to a building component, e.g., an I-beam  52 , by a washer  55  and nut  54 . A lower portion  51   b  of rod  51  is connected to the hub  14  by screwing a portion of the lower portion  51   b  of the rod  51  into a threaded hole drilled into a mounting block  56  attached to the sleeve  18   a.    
         [0049]    Rod  51  can be attached to sleeve  18   a,  plate  16   a,  or directly onto the sprinkler head assembly  44  by welding, bolting, clipping, or by screwing rod  50  into a threaded hole (as shown in FIG. 5), or by any other commonly known attachment mechanism.  
         [0050]    Rod  51  can be threaded or non-threaded and can be constructed from numerous materials, including but not limited to stainless steel, other steels, rubbers, plastics, polymers, ferrous metals, non ferrous metals, polycarbonates, or any combination thereof.  
         [0051]    Alternatives to using a rod  51  in an auxiliary support system  50  include a chain, wire or rope, all of which can be attached to the hub  14  or sprinkler head assembly  44 . These devices will similarly prevent the sprinkler head assembly  44  and decorative support panel  10  from falling during support structure failure. Further, in locations that experience frequent seismic events, a rod will transmit any shocks or vibrations directly from the building component to the support system. The more flexible devices will cushion the vibrations. However, flexible secondary support devices such as chains, wires, or ropes may not alone provide adequate support for the sprinkler head assembly during operation.  
         [0052]    As shown in FIG. 6, another decorative support panel  10   b  is shown with four support legs,  60   a - 60   d.  These support legs are formed from a rigid material able to maintain their rigidity in high temperature environments that would be present during a fire. The support legs are attached, e.g., by welding, to plate  16   b  of hub  14   b.  Each of the support legs,  60   a - 60   d,  extend from one of the four corners  61   a - 61   d  of plate  16   b  to the corresponding corners of decorative panel  12 . Additionally, each of the support legs,  60   a - 60   d,  include an angled foot  62   a - 62   d  which is configured to engage the ceiling frame  6  (shown in FIG. 1). During operation of the sprinkler head, support legs  60   a - 60   d  help to transfer forces caused by the back pressure to ceiling frame  6 . The support legs  60   a - 60   d  are substantially parallel with the plane of decorative panel  12  and are on the back surface of decorative panel  12 . However, in other separate embodiments, the support legs may be angled relative to the plane of the decorative or they may be completely or partially integrated within the decorative panel. Additionally, clips (not shown) may be attached between the ceiling frame  6  and the feet of the support legs  61   a - 61   d  in order further attach the decorative support panel to the ceiling frame  6 . In another embodiment, support legs,  60   a - 60   d,  may extend from each of the side edges  63   a - 63   d  of the plate  16   b  to the corresponding side edge of decorative panel  12 .  
         [0053]    As shown in FIG. 7, an additional embodiment of a decorative support panel  10   c  is shown. In this embodiment, the plate  16  (shown in FIGS.  1 - 6 ) and decorative panel  12  (shown in FIGS.  1 - 6 ) are integrated in a single-piece rigid decorative support panel  13 . Decorative support panel  13  is formed of a rigid material (e.g., aluminum, titanium, stainless steel and other steel alloys, ceramic, high temperature plastic) that is capable of withstanding the back pressure forces created by the flow of water through the sprinkler head during operation in a high temperature environment. Sleeve  18   c  is attached to rigid decorative support panel  13  and provides a housing for the sprinkler head assembly  44  (not shown in FIG. 7). Rigid decorative support panel  13  fits into rectangular frame section  8  and helps to hold sprinkler head assembly  44  in place during operation by distributing some of the forces created by the flow of water through the sprinkler head to the ceiling frame  6 . Additionally, the bottom surface (i.e., the surface exposed to the room) may be coated with a material to match the surface of other decorative panels  11  (as shown in FIG. 1).  
         [0054]    As shown in FIGS.  8 A- 8 B, another decorative support panel  10   d  includes two brackets  70   a - 70   b  attached to decorative panel  12   d  and plate  16   d.  Additionally, plate  16   d  includes four bolts  72   a - 72   d  which attach sleeve  18   d  to the decorative support panel  10   d.  Sleeve  18   d  includes a plate  71  which has four holes (not shown) corresponding to the four bolts  72   a - 72   d  mounted on plate  16   d.  Four nuts (not shown) may be screwed onto the four bolts  72   a - 72   d  to secure sleeve  18   d  to plate  16   d.  In another embodiment, the plate  16   d  may include support legs which are inclined from plate  16   d  to the four corners of the decorative panel  12 .  
         [0055]    As shown in FIG. 9, another decorative support panel  10   e  is shown. In this embodiment, plate  16   e  is attached to decorative panel  12  and includes a sleeve  18   e.  Sleeve  18   e  is a sliding slot for receiving a sprinkler head assembly. During assembly of sprinkler system  2 , sprinkler head assembly  44  is inserted through the larger hole  82  of sleeve  18   e  and then slid over to the smaller hole  84  of sleeve  18   e.  The diameter of the smaller hole  84  of sleeve  18   e  should be only slightly larger than the diameter of sprinkler head assembly in order to secure the sprinkler head assembly firmly to plate  16   e.    
         [0056]    As shown in FIG. 10, a decorative support panel  10   f  with a split-hub  14   f  is shown. In this embodiment, hub  14   f  includes two pieces,  15   a  and  15   b,  which together provide a channel to receive sprinkler head assembly  44 . One piece of the hub  15   a  includes a portion of the plate  17   a  and the sleeve  19   a.  The other piece of the hub  15   b  includes a second portion of the plate  17   b  and sleeve  19   b.  The two pieces of the hub  15   a,    15   b  are removably attached to each other by bolts (not shown), screws, pins, clips or other commonly known methods.  
         [0057]    As shown in FIG. 11, another decorative support panel  10   g  with a ring-shaped hub  14   g  is shown. In this embodiment, hub  14   g  is ring-shaped and is attached to decorative panel  12 . The opening of hub  14   g  defines the sleeve  18   g  and is configured to receive a sprinkler assembly  44  (not shown in FIG. 11). Hub  14   g  is also supported by four legs  90   a - 90   d,  which extend from hub  14   g  to the center of each of the four edges of the decorative panel  12 . Each of the four legs  90   a - 90   d,  include a foot  92   a - 92   d  attached at the end of each leg. When decorative support panel  10   g  is placed in a rectangular frame section  8  of the ceiling frame  6  (as shown in FIG. 1), the four feet  92   a - 92   d  attached at the end of each leg  90   a - 90   d  engage the ceiling frame  6  and thus provide additional support of the sprinkler head assembly. Additionally, the four legs  90   a - 90   d  may be further secured to the ceiling frame  6  with clips, pins, bolts, nails, screws or other commonly known methods.  
         [0058]    A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the previous embodiments have described a sprinkler support system housed in a ceiling. However, a sprinkler support system may be housed in a wall or floor having an array of panels supported by a frame.  
         [0059]    Accordingly, other embodiments are within the scope of the following claims.