Abstract:
Prefabricated frames and fabrication methods thereof are disclosed. The prefabricated frames comprise substantially L-shaped frame members. In addition, spreader members and space adaptors coupled to the substantially L-shaped frame members adapt the prefabricated frames to the size and shape of a ceiling opening. The prefabricated frames are attached within the ceiling opening. A receiver member with a configuration adaptable for various sized ceiling openings is attached within the ceiling opening and permits an interior dome to be coupled to the substantially L-shaped frame members. When the receiver member has a recess and through hole to permit installation of a ceiling fan within the prefabricated frames, the ceiling fan is attached to the receiver member.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates generally to prefabricated frames and methods for the fabrication thereof and, more specifically, to prefabricated frames for ceiling fans and methods for fabrication thereof  
         BACKGROUND OF THE INVENTION  
         [0002]    In the past, various types of lighting systems for use in a room were developed. For example, initially use was made of incandescent lighting systems to provide lighting within a room. Subsequently, fluorescent lighting systems were developed because of the greater amount of light and lower costs associated with the use of fluorescent lights versus incandescent lights.  
           [0003]    Current grid work type fluorescent lighting is common in construction applications where it is desirable to hide fluorescent bulbs from observers. Fluorescent lighting provides greater lumens than common light bulbs based on the wattage used. Fluorescent bulbs installed in an opening between an actual ceiling and a grid work frame are hidden by diffuser panels placed on the grid work frame resulting in a softer and more pleasing lighting effect. An example of a ceiling with an opening between an actual and a grid work frame is a soffit in a kitchen.  
           [0004]    Many grid work frame ceilings are low in height and often observers prefer a feeling of greater height. Grid work frames with lowered ceilings are usually flat and take no advantage of the depth between the actual ceiling and grid work frames to provide greater height.  
           [0005]    Usually fluorescent lights are parallel banks of fluorescent bulbs adjacent to two opposing walls, and attached to the actual ceiling within the opening and above the grid work frame. The fluorescent lights are behind diffuser panels within the grid work frame. Such construction limits the amount of lighting that is available and does not take advantage of attaching banks of fluorescent bulbs to the actual ceiling and adjacent to all available sidewalls within the opening above the grid work frame.  
           [0006]    In many cases, observers may install ceiling fans to provide air circulation. Installing a ceiling fan into a ceiling below the height of the ceiling is possible. However, this further limits the feeling of height to the observer and takes no advantage of the space between the grid work frame and the actual ceiling above the grid work frame.  
           [0007]    Current grid work frames are integral structures, which are expensive and difficult to replace. Installation of grid work frames occurs on-site and requires professional installation.  
           [0008]    For the foregoing reasons, there is a need to provide a kit, frame structure and method of fabrication for easy installation of a prefabricated frame to replace a current grid work frame where it is desirable to provide greater ceiling height and illumination from banks of fluorescent bulbs. This kit may also provide for installation of a ceiling fan within the prefabricated frame, so that the entire structure is a prefabricated frame for a ceiling fan.  
         SUMMARY OF THE INVENTION  
         [0009]    Accordingly, it is an object of this invention to provide a prefabricated frame assembly and method of installation of the prefabricated frame assembly.  
           [0010]    It is a further object of this invention to provide a prefabricated frame assembly that can be transported as a kit.  
           [0011]    It is a still further object of this invention to provide a prefabricated frame assembly kit that can be custom modified to facilitate installation thereof for various sized openings.  
           [0012]    It is another object of this invention to provide a prefabricated frame assembly and method of installation thereof for use with a ceiling fan to be located within the prefabricated frame kit assembly.  
         PREFERRED EMBODIMENTS OF THE INVENTION  
         [0013]    In accordance with one embodiment of this invention, a prefabricated frame assembly comprises, in combination, a plurality of substantially L-shaped frame members and means for connecting together the plurality of substantially L-shaped frame members to form a frame. The prefabricated frame assembly is a ceiling frame assembly. The prefabricated frame assembly includes a ceiling fan coupled to the ceiling frame assembly. The plurality of substantially L-shaped frame members have configurations to adapt the prefabricated frame assembly to the size and shape of a ceiling opening. The ceiling frame assembly includes spreader members coupled to the substantially L-shaped frame members. The ceiling frame assembly also includes space adaptors coupled to the substantially L-shaped frame members. The ceiling frame assembly further includes an interior dome coupled to the substantially L-shaped frame members. The ceiling frame assembly still further includes a flat receiver member connected to the interior dome. The receiver member has a configuration adaptable for various sized ceiling openings. The receiver member also has a recess and a through hole to permit installation of the ceiling fan within the prefabricated frame assembly. The receiver member further includes the ceiling fan attached to the receiver member.  
           [0014]    In accordance with a second embodiment of this invention, a method for fabricating a frame assembly comprises the steps of providing a plurality of substantially L-shaped frame members and connecting together the plurality of substantially L-shaped frame members to form a frame. The method further includes the step of attaching spreader members coupled to the substantially L-shaped frame members. The method further includes the step of attaching space adaptors coupled to the substantially L-shaped frame members. The method further includes the step of attaching the frame assembly within a ceiling opening. The method still further comprises the steps of attaching a receiver member to the ceiling opening within the frame assembly and a ceiling fan to the receiver member. The method still further comprises the step of forming an interior dome coupled to the plurality of substantially L-shaped frame members.  
           [0015]    The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more detailed description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    [0016]FIG. 1 is a bottom perspective view of a prefabricated frame assembly surrounding a ceiling fan recessed within frame members of the prefabricated frame assembly;  
         [0017]    [0017]FIG. 2 is a bottom plan view of the prefabricated frame assembly of FIG. 1;  
         [0018]    [0018]FIG. 3 is a top perspective view of the frame members of the prefabricated frame assembly of FIG. 1;  
         [0019]    [0019]FIG. 4 is a cross section view through  4 - 4  of FIG. 3 of a nailer attached to the frame member on an enlarged scale;  
         [0020]    [0020]FIG. 5 is a cross section view through  5 - 5  of FIG. 3 of in line fastener members attached to the frame members on an enlarged scale;  
         [0021]    [0021]FIG. 6 is a cross section elevation view through  6 - 6  of the prefabricated frame assembly of FIG. 1;  
         [0022]    [0022]FIG. 7 is a perspective view of an inner corner of a dome of the prefabricated frame assembly shown in FIG. 1;  
         [0023]    [0023]FIG. 7A is a perspective view of a notched seam strip at the corner of the dome shown in FIG. 7; and  
         [0024]    [0024]FIG. 8 is a bottom perspective view of a recess and a through hole for fan leads essentially centered within the recess of a receiver member of the prefabricated frame assembly of FIG. 1.  
     
    
     DESCRIPTION OF THE INVENTION  
       [0025]    Referring to FIG. 1, a prefabricated frame assembly comprises a plurality of frame members  10  and a receiver member  18  surrounding a ceiling fan  12  mounted therein. A plurality of flat light diffuser panels  20  mounted within the frame members  10  provide for diffused lighting when illuminated by fluorescent lighting behind the flat light diffuser panels  20 . According to FIG. 1 and FIG. 6, a multiplicity of curved light diffuser panels  22  held by tension between the frame members  10  and the receiver member  18  form a dome  78  in a ceiling opening  76  (see FIG. 6). In FIG. 1, a seam strip  24  connects each curved light diffuser panel  22  on the exterior surface of the dome  78 , except at each ceiling corner of the dome  78  where a notched seam strip  26  connects the curved light diffuser panels  22  on the exterior surface of the dome  78 .  
         [0026]    In FIG. 2 in this embodiment, the frame members  10  comprise four substantially L-shaped members  14 , where each substantially L-shaped frame member has a first leg  54  and a second leg  56  and the angle between the first leg and the second leg is a right angle. Two spreader members  16  are aligned between two of the four substantially L-shaped frame members  14 .  
         [0027]    Substantially L-shaped members  14  means the angle between the first leg  54  of the L-shaped member  14  and the second leg  56  of the L-shaped member  14  is equal to a right angle or an obtuse angle, depending on the shape of the assembled frame members  10 . For example, when assembled frame members  10  make a rectangle, the angle is a right angle. When assembled frame members  10  make an octagon, the angle is obtuse.  
         [0028]    According to FIG. 2 and FIG. 6, curved light diffuser panels  22  extend from the assembled frame members  10  to an indentation formed between a receiver front panel  28 , which has a chamfered edge and to a back frame  30  located on the back of the receiver member  18 , which is flat. In this embodiment, the receiver front panel  28  has a recess  32  (see FIGS. 2 and 8) essentially centrally located in the receiver front panel  28  for receiving a fan front plate  36  (see FIG. 6). Within the recess  32  the receiver front panel  28  has a through hole  34  that is a conduit for fan leads  70  (see FIG. 6). The receiver front panel  28  provides a decorative ceiling within the dome  78 .  
         [0029]    Two common construction terms are used in this description, viz. a nailer and a waler. A nailer is a structural element attached to a member whose purpose is to provide a means for fastening the member to a surface. In construction, a common fastener is a nail (from which the term derives). A waler is another structural element whose purpose is to act as a strengthening and framing element attached to the surface of a member.  
         [0030]    According to FIG. 3, each substantially L-shaped frame member  14  has an in line fastener  48  attached at a first end  44  of the substantially L-shaped frame member  14  and an in line fastener  48  attached at a second end  46  of the substantially L-shaped frame member  14 . Each of the in line fasteners  48  have a multiplicity of predrilled in line holes  50  for receiving a multiplicity of in line screws  52  to couple frame members  10  to one another. The substantially L-shaped frame member  14  further has a waler  58  extending from the first end  44  of the substantially L-shaped frame member 14  affixed along the inner periphery of the first leg  54  of the substantially L-shaped frame member  14 . A waler  58  extends from the second end  46  along the inner periphery of the second leg  56  of the substantially L-shaped frame member  14  and adjoins the waler  58  of the first leg  54 . In addition, the substantially L-shaped frame member  14  further has a multiplicity of nailers  40  affixed near the inner edge of the outer periphery of the substantially L-shaped frame member  14 , each nailer  40  having a predrilled inclined hole  42  for fastening to a sidewall  68  of the ceiling opening  76 . The walers  58 , nailers  40  and in line fasteners  48  of each substantially L-shaped frame member  14  are affixed to a surface on the same side of the substantially L-shaped frame member  14 .  
         [0031]    According to FIG. 3, each spreader member  16 , is aligned and fastened between the second ends  46  of substantially L-shaped frame members  14 . Each spreader member  16  has an in line fastener  48  attached at each end of the spreader member  16 . The in line fasteners  48  attached to the spreader member  16  have predrilled in line holes  50 , corresponding to the predrilled in line holes  50  of the in line fasteners  48  of the substantially L-shaped frame members  40 , for receiving in line screws  52  to affix the second ends  46  of the substantially L-shaped frame members  14 . The spreader has a waler  58  extending from the in line fasteners  48  at each end of the spreader member  16  and within the inner periphery of the spreader member  16 . The spreader member  16  further has a multiplicity of nailers  40  affixed near the inner edge of the outer periphery of the spreader member  16 , each nailer  40  having a predrilled inclined hole  42  for fastening to the sidewalls  68  of the ceiling opening  76 . The nailers  40 , waler  58 , and in line fasteners  48  of each spreader member  16  are affixed to a surface on the same side of the spreader member  16 . The walers  58  provide structural integrity for the frame members  10  and limit the movement of the flat light diffuser panels  20  and the curved light diffuser panels  22 .  
         [0032]    According to FIG. 3 a space adaptor  60  aligned and fastened between the first ends  44  of the substantially L-shaped frame member  14  allows for a better fit of the assembled frame members  10  within the ceiling opening  76 , when this modification is necessary. The space adaptor  60  has an in line fastener  48  at each end of the space adaptor  60 . The in line fasteners  48  of the space adaptor  60  have predrilled holes  50 , corresponding to predrilled holes  50  of the in line fasteners  48  of the substantially L-shaped frame members  14 , for receiving screws  52  to affix the first ends  44  of the substantially L-shaped frame members  14 . The in line fasteners  48  of the space adaptor  60  are attached to a surface on the same side of the space adaptor  60 .  
         [0033]    Referring to FIG. 4, which is a cross section at  4 - 4  in FIG. 3, the nailer  40  having the predrilled inclined hole  42 , is located near the edge of the outer periphery of the first leg  54  of the substantially L-shaped frame member  14 . In addition, the in line fastener  48  having the predrilled holes  50  butts up against the waler  58 , which is within the inner periphery of the first leg  54  of the substantially L-shaped frame member  14 .  
         [0034]    [0034]FIG. 5, which is a cross section at  5 - 5  in FIG. 3, shows further detail where the aligned in line fasteners  48  at the first ends  44  of the substantially L-shaped frame members  14  are fastened with the in line screw  52 .  
         [0035]    According to FIG. 6, which is a cross section at  6 - 6  of FIG. 1, the assembled frame members  10  are attached to the sidewalls  68  of the ceiling opening  76  with a plurality of nailer screws  74 . The assembled frame members  10  suspended by wires  64 , provide further structural stability. The wires  64  are attached to the ceiling  66  and hooks  62  on the assembled frame members  10 . The curved light diffuser panels  22  are fixed in place by tension and extend from the waler  58  of the first leg  54  of the substantially L-shaped frame member  14  to the indentation between the receiver front panel  28  and the back frame  30 . A multiplicity of fluorescent lighting fixtures  72  are fastened to the ceiling  66  above the flat light diffuser panels  20  that are within the frame members  10 . According to this embodiment, the receiver member  18  comprises the receiver front panel  28  having the recess  32  and the through hole  34 , the fan front plate  36 , the back frame  30  and a fan back plate  38  having the through hole  34  for the fan leads  70 . The fan back plate  38  is attached to the back of the receiver front panel  28  and strengthens the receiver member  18  when the fan  12  is attached to the face of the receiver member  18  (see FIGS. 6 and 8).  
         [0036]    According to FIG. 7, the dome  78  has curved light diffuser panels  22  fixed in place by tension extending from walers  58  to the indentation between the receiver front panel  28  and the back frame  30 . Seam strips  24  fixed in place by tension connect the curved light diffuser panels  22  on the exterior of the dome  78 , and provide a finished appearance to the dome  78 . The seam strips  24  fixed in place by tension, extend from the walers  58  to the indentation between the receiver front panel  28  and the back frame  30 . Notched seam strips  26  on the exterior of the dome  78  connect the curved light diffuser panels  22 , which meet at a ceiling corner. FIG. 7A is a detailed perspective view of the notched seam strip  26  with a notch  80  at one end. The notched seam strip  26  fixed in place by tension extends from the corner where walers  58  adjoin, with the notch  80  fitting into the indentation at the ceiling corner between the receiver front panel  28  and the back frame  30 .  
         [0037]    A description of the installation method for the prefabricated frame assembly follows. The frame members  10  are joined by aligning and fastening the substantially L-shaped frame members  14 , spreader members  16 , and when necessary, the space adaptors  60  using in line screws  52 . The current flourescent lighting fixtures  72  are relocated so they are fastened to the ceiling  66  above the measured position of the flat light diffuser panels  20  in the assembled frame members  10 . The assembled frame members  10  are affixed to the sidewalls  68  of the ceiling opening  76  using nailer screws  74 . In addition, the assembled frame members  10  are attached to the ceiling  66  by wires  64 . The receiver member  18  (pre-customized to fit the ceiling opening  76 ) is attached to the ceiling  66  at ceiling joists, which provides strength of attachment for the receiver member  18  to the ceiling  66 . The flat light diffuser panels  20  are placed within the frame members  10  extending from the ends of the frame members  14  and bounded between walers  58  and in line fasteners  48 . The curved light diffuser panels  22  are placed between the walers  58  and the indentation between the receiver front panel  28  and back frame  30 , except where the curved light diffuser panels  22  meet at the ceiling corners of the dome  78 . In this embodiment, half the curved light diffuser panels  22  intended for the corners of the dome  78 , are marked and cut to the curvature of the corners of the dome  78 . These cut diffuser panels  22  mounted by tension between the walers  58  and the indentation between the receiver front panel  28  and back frame  30  meet the remaining half of uncut curved light diffuser panels  22  at each corner of the dome  78 . Longer seam strips  24  are custom cut to provide seam strips  24  to fit between curved light diffuser panels  22  and notched seam strips  26  to fit at the corners of curved light diffuser panels  22 , to complete the dome  78 . In this embodiment, the fan  12  is attached to the face of the receiver member  18 .  
         [0038]    The frame members  10 , pre-customized receiver member  18 , space adaptors  60 , lengthened seam strips  24 , flat light diffuser panels  20  and diffuser panels to be used as curved light diffuser panels  22 , in line screws  52  and nailer screws  74 , together with installation instructions described above are a kit for making the prefabricated frame assembly. The installation instructions show stepwise methods, diagrams and photographic reproductions, and recommendations for installing the kit so that a non-professional may install the kit. Other construction components commonly used in construction finishing may also be included in the kit. The receiver member  18  having the recess  32  and thc through hole  34  is optional depending on whether the ceiling fan  12  is to be installed The kit is easily shipped and parts are readily replaced. Frame members  10  are extendable at regular intervals allowing flexibility in the kit design. Additional fluorescent lighting fixtures  72  may be added when the old fluorescent lighting fixtures  72  are relocated.  
         [0039]    In summary, the present invention is directed to a kit, frame structure and method of fabrication for easy installation of a prefabricated frame to replace a current grid work frame where it is desirable to provide greater ceiling height and illumination from banks of fluorescent bulbs, and allow installation of a ceiling fan within the frame structure if desired. The kit comprises frame members, which are fastened to provide a prefabricated frame that fits an opening within the current grid work frame structure, and replaces the grid work frame. The prefabricated frame is fastened to the sidewalls of the opening. Diffuser light panels are placed in the prefabricated frame and allow more fluorescent lighting to be added above each of the diffuser light panels. The kit has a receiver member included for attachment to the ceiling that receives curved light diffuser light panels held in place by tension from the prefabricated frame and gives the appearance of a dome. The receiver member may have a through hole for fan loads to allow installation of a ceiling fan. The receiver member also acts as the finished ceiling for the prefabricated frame structure. The kit has long seam strips that are cut to shape as notched seam strips for corner seams in the dome and seam strips at open edges where diffuser panels meet.  
         [0040]    While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention,  
         [0041]    For example, the prefabricated frame kit can be altered in various ways within the basic concept of this invention. In particular, it is possible to assemble the prefabricated frame so that the frame&#39;s shape conforms to geometric openings such as octagons rather than Squares and rectangles. The materials of construction of the prefabricated frame can be altered. Examples of materials are common construction materials such as wood and its various products, medium density fiber, plastics and metals. In addition, other fastening methods may be used. Nut and bolt systems or snapping systems, which are commonly used for plastics, illustrate some alternative fastening methods. Seam strips are flexible materials. Diffuser panels made from flexible light diffusing materials having different grades, textures, colors and finishes. Various decorative designs can be used for the receiver member and the frame members.