Abstract:
Various systems including brackets and associated wires are disclosed for suspending fixtures from ceilings and the like. The systems improve over the prior art in several ways. Attachment of the wire to the bracket is faster and easier. The attachment can be made more rigid. Several different components can be combined to adapt to different suspension requirements. Brackets can be provided with structure to make more stable connections to cement and masonry.

Description:
This application is a continuation of application Ser. No. 10/448,951 filed May 30, 2003 now U.S. Pat. No. 7,341,232 which claims the benefit of provisional application Ser. No. 60/384,675 filed May 31, 2002, is a continuation-in-part of my prior application Ser. No. 10/092,741 filed Mar. 7, 2002 now U.S. Pat. No. 7,025,317, the complete disclosure of which is hereby incorporated by reference herein and is also a continuation-in-part of my prior application Ser. No. 10/134,229 filed Apr. 26, 2002 now U.S. Pat. No. 6,669,158, the complete disclosure of which is hereby incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to mechanical fasteners. More particularly, the invention relates to mechanical fasteners suitable for suspending fixtures such as acoustic tile ceilings, pipes, lighting fixtures, electrical cables, HVAC equipment etc. 
     2. State of the Art 
     Current practice in the construction trade and building industry is to suspend fixtures with wires which are fastened to a wall or ceiling. An example of a state of the art apparatus for suspending fixtures is illustrated in prior art  FIG. 1 . The apparatus generally includes an angle bracket  10  having two holes  12 ,  14 , a fastener  16  (typically a nail or a screw), and a length of wire  18  (often six to eight feet long). The method for using the apparatus includes attaching the wire  18  through one of the holes  14 , inserting the fastener  16  through the other hole  12 , and fastening the fastener  16  to a wall or ceiling  20 . An exemplary bracket and fastener are illustrated in U.S. Pat. No. 5,178,503 and U.S. Pat. No. 4,736,923. 
     The apparatus shown in  FIG. 1  is often used to suspend fixtures from cement, stone, or other masonry material ceilings, typically in commercial buildings. The wires  18  are attached to ceiling tile grids, pipe brackets, HVAC ducts, lighting fixtures, etc. Because a relatively large variety of equipment is hidden above a suspended acoustic tile ceiling in a commercial building, the wires  18  are often six to eight feet long. 
     The fastener  16  is usually pre-fit into the hole  12  of the bracket  10  during manufacture. However, the wire  18  (usually 12 gauge galvanized steel) must be manually attached to the bracket  10  by inserting a free end of the wire through the hole  14 , looping the wire onto itself and twisting it as shown in  FIG. 54 . This is often done by hand with a pair of pliers or may be done with the aid of a hand operated (or drill operated) crank such as the “wire tying fixture”, item number 00052075, sold by Hilti, Inc., Tulsa, Okla. These methods of attaching the wire to the bracket present several disadvantages. 
     The most apparent disadvantage is the cost of labor for the labor intensive task of twisting the wire. In order to be reasonably secure and satisfy some municipal codes, approximately eight inches of the wire must be twisted eight to ten turns about itself. In practice, many workers only twist the wire three or four times about itself. Still, the work is time consuming. The best productivity is not much more than about 300 pieces per hour and after about 500 pieces the worker needs to rest. 
     Another disadvantage is that this method of connecting the wire to the bracket is not very secure. Under a stress of about 50 lbs., the wire loop stretches and under a stress of about 210 lbs. the wire untwists. 
     Still another disadvantage is that the connection between the wire and the bracket is loose. Under normal circumstances, gravity provides tension between the wire and the bracket. However, in the case of an earthquake or a fire, the loose connection between the wire and the bracket allows vibration and movement of the fixtures supported by the wire. This can result in fixtures falling onto emergency workers and other similar hazards. 
     Yet another disadvantage is that if the bracket becomes damaged, the wire attached to it is usually wasted. For example, many brackets are manufactured with fasteners pre-attached so that the bracket may be installed quickly without holding both the bracket and fastener in place. If the fastener detaches from the bracket after the wire is attached but before the bracket is installed, or if the fastener fails to fasten properly, the bracket with the attached wire is typically discarded, thus wasting the wire. 
     It is estimated that the annual sale of brackets and wires is in excess of one hundred million. It is also estimated that the failure rate is 12-20%. The average wire length is six feet. Thus, approximately 72-120 million feet of wire goes to waste. 
     My first prior application, referenced above, discloses an angle bracket with a hole for a fastener and a flange for coupling a wire to the angle bracket. The flange is lanced and it is coupled to the wire by crimping. According to a first embodiment, the flange is provided with two horizontal lances. According to a second embodiment, the flange is provided with at least three alternating horizontal lances. According to a third embodiment, the flange is provided with a horizontal lance and a vertical lance. According to a fourth embodiment, the flange is provided with a vertical lance in the shape of a hook and an eyelet is provided for connecting the wire. According to a fifth embodiment, the flange is wrapped to form a slotted cylinder. The wire is inserted into the slotted cylinder which is then compressed and crimped onto the wire. According to a sixth embodiment, the angle bracket is provided with two wire connecting flanges. A seventh embodiment is similar to the sixth embodiment with features of the second embodiment. A kit is also disclosed which includes a plurality of lanced angle brackets, a plurality of pre-cut lengths of wire, and a combined crimping and testing tool. 
     My second prior application, referenced above, discloses an angle bracket with a hole for a fastener and a flange with a hole for receiving a wire and a wire with a deformation or attachment at one end which prevents it from passing completely through the hole in the flange of the bracket. Six embodiments of a bracket are disclosed. Eight embodiments of a wire are disclosed. The wires may be used with prior art brackets with little or no modification to the bracket. An unmodified prior art bracket is shown in conjunction with wires according to the invention and a slightly modified prior art bracket is shown with a wire according to the invention. 
     Although the methods and apparatus disclosed in my prior applications are improvements over the prior art, it is my intention to provide yet additional methods and apparatus which overcome disadvantages of the prior art. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the invention to provide improved methods and apparatus for suspending fixtures. 
     It is also an object of the invention to provide methods and apparatus for suspending fixtures which are not labor intensive. 
     It is another object of the invention to provide methods and apparatus for suspending fixtures which are more economical than the state of the art. 
     It is still another object of the invention to provide methods and apparatus for suspending fixtures which are safer and stronger than the state of the art. 
     It is yet another object of the invention to provide methods and apparatus for suspending fixtures which provide brackets and wires which are easily coupled and uncoupled. 
     In accord with these objects which will be discussed in detail below, the apparatus of the present invention includes an angle bracket with a hole for a fastener and a hole for coupling a wire to the angle bracket. Wires according to one aspect of the invention include a collar for forming a loop through the hole in the angle bracket. Three embodiments of wires with collars are disclosed. According to one embodiment, the collar is a slotted cylinder which is crimped to the wire at the time it is attached to the bracket. According to a second embodiment, the collar is crimped to the wire at the factory and has a J-shaped extension which allows the end of the wire to be engaged by the collar in a manner similar to a safety pin. According to a third embodiment, the collar is made of a loop of wire which is twisted several times at the time it is attached to the bracket. Wires according to another aspect of the invention are provided in two parts with a crimpable structure for joining the wires. According to this aspect of the invention, the length of the wire assembly can be adjusted without cutting wire. A new angle bracket according to the invention includes a tongue formed by lancing. The tongue prevents wire from escaping. Three other embodiments of wires and brackets following from my second previous application are also disclosed. According to another aspect of the invention, a wire is provided with two bends at one end which may be slipped through the wire-receiving hole of a conventional bracket and hooked upon itself. 
     Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic side elevational view, in partial section, of a state of the art apparatus for suspending fixtures; 
         FIG. 2  is a partially transparent schematic side elevational view of a first embodiment of the invention; 
         FIG. 2   a  is a top plan view of the collar of the first embodiment; 
         FIG. 2   b  is a rear side elevational view of the collar of the first embodiment; 
         FIG. 3  is a view similar to  FIG. 2  with a slightly different loop in the wire; 
         FIG. 4  is a partially transparent schematic side elevational view of a second embodiment of the invention, partially assembled; 
         FIG. 4   a  is a bottom plan view of the collar of the second embodiment; 
         FIG. 5  is a view similar to  FIG. 4  showing the wire fully engaged by the collar; 
         FIG. 6  is a partially transparent schematic side elevational view of a third embodiment of the invention, partially assembled; 
         FIG. 6   a  is a plan view of the wire used to form the collar of the third embodiment; 
         FIG. 7  illustrates an embodiment of a two part wire assembly according to the invention in conjunction with a bracket and a hanging structure; 
         FIG. 8  illustrates the two part wire assembly without the bracket and hanging structure; 
         FIG. 9  illustrates an embodiment of an angle bracket with a tongue; 
         FIGS. 10-12  illustrate alternate embodiments of a wire and bracket structure as described in my second parent application; 
         FIGS. 13 and 14  illustrate a wire similar to the wire illustrated in  FIG. 6  but configured to hook onto itself without a collar; 
         FIGS. 15 and 16  illustrate the wire of  FIG. 11  with a modified prior art bracket; 
         FIG. 17  illustrates an angle bracket having an extruded funnel; 
         FIG. 18  illustrates the angle bracket of  FIG. 17  installed with a nail in a cement ceiling; 
         FIG. 19  illustrates a bracket similar to  FIG. 17  but designed to secure a conduit or cable; 
         FIG. 20  illustrates an angle bracket having a tongue for engaging the loop of a wire; 
         FIG. 21  illustrates the looped wire used with the bracket of  FIG. 20 ; 
         FIG. 22  illustrates an angle bracket having a pair of slots for engaging a hook shaped wire; 
         FIG. 23  illustrates one embodiment of the bracket of  FIG. 22 ; 
         FIG. 24  illustrates another embodiment of the bracket of  FIG. 22 ; 
         FIG. 25  illustrates an angle bracket for use with a wire having a T-shaped end; 
         FIG. 26  is a top view of the bracket of  FIG. 25 ; and 
         FIG. 27  is a broken side elevational view of a wire with a T-shaped end. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to  FIGS. 2 ,  2   a , and  2   b , a first embodiment of the invention is illustrated with a conventional angle bracket fastener  100 . The angle bracket  100  has a first flange  102  and a second substantially orthogonal flange  104 . The first flange  102  has a first hole  106  for receiving a fastener such as the nail  108 . As illustrated, the nail  108  is premounted in the hole  106  and is provided with a collar  109  which facilitates aiming and firing the nail with a gun (not shown). The flange  104  is provided with a hole  110  for receiving a wire. 
     The wire  112  according to the invention has a first end  114  and a second end  116 . Though illustrated as a short wire, the wire  112  is typically six feet or longer. The wire  112  is preferably provided with a loop  118  so the end  114  comes adjacent to an earlier portion of the wire. According to the invention, a crimpable collar  120  is provided. The collar  120  is substantially cylindrical and is preferably a slotted cylinder as shown in  FIGS. 2   a  and  2   b . According to a method of the invention, after the loop  118  is formed and the end  114  is passed through the hole  110  in the flange  104 , the collar  120  is slipped over the end  114  and the adjacent portion of the wire  112  and is then crimped. 
     According to the first embodiment of the invention, the wire  112  is pre-formed with the loop  118 . The loop is passed through the hole  110  on-site and the collar is also applied and crimped on-site. However, the wire with the collar could be attached to the bracket at the factory if desired. 
       FIG. 3  shows a slightly different version of the first embodiment. Here the wire  212  has slightly different shaped loop  218 . From the foregoing described  FIGS. 2 and 3 , those skilled in the art will appreciate that the loop at the end of the wire need not be preformed. According to an alternate method of the invention, an on-site worker is provided with brackets, wires, collars, and a crimping tool. The on-site worker threads and loops a wire onto a bracket, slips the collar over the wire and crimps the collar to achieve a configuration similar to that shown in  FIGS. 2  and/or  3 . 
       FIGS. 4 ,  4   a  and  5  illustrate a second embodiment of a wire with a collar for use with a prior art angle bracket  100 . The wire  312  has a first end  314  and a second  316 . A loop  318  is formed near the end  314  and a substantially “g-shaped” collar is attached to the wire before the loop  318 . The collar has a closed portion  320   a  which is crimped to the wire  312  and a substantially “J-shaped” open portion  320   b  which extends outward. As shown in  FIGS. 4 and 5 , the end  314  is provided with a substantially 180° bend  319 . As shown in  FIG. 5 , a portion of the wire before the bend  319  is captured by the open portion  320   b  in a manner similar to that of a safety pin. Thus, it will be appreciated that the bend  319  is optional. 
     According to this embodiment, the bend  318  and optionally  319  are formed in the factory where the collar  320  is crimped to the wire. The on-site worker can then insert the end  314  through the hole  110  in the clip  100  and fasten the wire by engaging the end in the open portion  320   b  of the collar  320 . 
       FIGS. 6 and 6   a  illustrate an embodiment similar to that shown in  FIGS. 4 and 5  but where the collar is formed by a twisted wire. As shown in  FIG. 6 , the wire  412  has a first end  414 , a second end  416  and two bends  418  and  419  similar to the wire  312 . Here the area of the wore adjacent the bend  319  is secured to an area before the bend  318  by a twisted wire  420 . The wire  420  is preferably applied with a twisting device (not shown). 
       FIGS. 7 and 8  illustrate a two part wire assembly which can be adjusted lengthwise on-site without cutting wire. As shown in  FIG. 7 , a bracket  500  of the type disclosed in my second parent application includes two parallel flange  502 ,  504  with a bowl-like hole  510  in the second flange  504 . A first wire  512  has a first end  514 , a second end  516  and a loop  518  formed near the first end  514 . The loop  518  prevents the wire from passing completely through the hole  510 . A second similar wire  522  is provided having a first end  524 , a second end  526 , and a loop  528  near the second end  526 . The loop  528  is used to engage a hole in a hanging structure  530  such as a frame for an acoustic tile ceiling or the like. According to this embodiment of the invention, the first wire  512  and the second wire  522  are coupled to each other by a crimpable collar  520 . As shown in  FIGS. 7 and 8 , the collar  520  is a sheet of metal which has been lanced in several places to provide two openings for receiving the wires. This type of lancing is shown and described in my first parent application, previously incorporated hereinabove. Those skilled in the art will appreciate that it will be advantageous to lance in one direction for one wire and in the other direction for the other wire so that the wires pass on opposite sides of the metal sheet. When the two wires are inserted into the collar  520 , they can be moved longitudinally so as to adjust the overall length of the two wire and collar assembly. According to a method of the invention, the collar  520  is crimped to the upper wire  512  and the lower wire  522  is moved through the collar. When the overall length of the wire assembly is decided, the lower wire  522  can be bent slightly as shown in  FIG. 8  to maintain its position temporarily while the collar  520  is crimped to it. 
       FIG. 9  illustrates an angle bracket  600  having a tongue  611 . The angle bracket  600  is similar to those described in my second parent application, having an upper flange  602  and a substantially parallel lower flange  604 . The lower flange  604  is provided with a bowl-like hole  610  which receives and captures the upper loop of a wire  512 . According to this embodiment, a portion of the bracket  600  (above the lower flange) is lanced to create a tongue  611  which can be bent down on top of the loop in wire  512  to prevent the wire from escaping the bracket. Those skilled in the art will appreciate that the tongued bracket can be used with several of the different wire embodiments disclosed in my second parent application. 
       FIGS. 10-12  illustrate wires of the type discussed in my second parent application but where the deformation at the upper end of the wire is relatively small and thus requires the use of a bracket with a wire hole not too much larger than the diameter of the wire. 
       FIG. 10  illustrates a wire  712  in conjunction with a bracket  700  having two parallel flanges  702 ,  704  similar to those described in my second parent application. The bracket  700  has a wire-receiving hole  710  in the second flange  704 . The diameter of the whole  710  is preferably only large enough to allow the wire  712  to pass through without difficulty. The wire  712  has a first end  714  and a second end  716 . The first end  714  is provided with a deformation  718 , in this case a Z-bend, which allows the first end of the wire to be passed carefully through the hole  710  but which prevents the wire from passing back out when the bracket  700  and wire  712  are in hanging relationship as shown in  FIG. 10 . 
       FIG. 11  illustrates a wire  812  in conjunction with a bracket  800  which is similar to a prior art bracket. The bracket  800  has a wire-receiving hole  810  with a diameter preferably only large enough to allow the wire  812  to pass through without difficulty. The wire  812  has a first end  814  and a second end  816 . The first end  814  is provided with a deformation  818 , in this case a Z-bend, which allows the first end of the wire to be passed carefully through the hole  810  but which prevents the wire from passing back out when the bracket  800  and wire  812  are in hanging relationship as shown in  FIG. 11 . 
       FIG. 12  illustrates a wire  912  in conjunction with a bracket  800  which is similar to a prior art bracket. The bracket  800  has a wire-receiving hole  810  with a diameter preferably only large enough to allow the wire  812  to pass through without difficulty. The wire  912  has a first end  914  and a second end  916 . The first end  914  is provided with a deformation  918 , in this case a U-bend, which allows the first end of the wire to be passed carefully through the hole  810  but which prevents the wire from passing back out when the bracket  800  and wire  912  are in hanging relationship as shown in  FIG. 12 . 
       FIGS. 13 and 14  illustrate a wire  1012  which may be used with any conventional bracket  100 . The wire  1012  has a first end  1014  and a second end  1016 . The first end of the wire is provided with two bends  1018  and  1019 . The bends are configured so that the wore may be passed through the hole  110  in a conventional bracket  100  and then hooked onto itself as illustrated in  FIG. 14 . 
       FIGS. 15 and 16  illustrate the wore  812  with a modified prior art bracket  101 . The only modification to the bracket is the diameter of the hole  111  which is made closer to the diameter of the wire  812 . 
     Turning now to  FIGS. 17 and 18 , an angle bracket  1100  according to the invention has a first end  1104  and a second end  1104 , a hole for receiving a nail  16  and a hole  1108  for receiving wire  812 . The nail receiving hole  1106  is provided with a funnel-like structure  1110  which will fill in the cavity  21  normally formed in cement  20  by the nail  16 . 
       FIG. 19  illustrates a bracket  1200  having a first end  1202 , a second end  1204 , a nail receiving hole  1206  and a funnel-like structure  1210  substantially the same as the funnel-like structure  1110  described above. The end  1204  of this bracket is designed to hold a conduit or cable (not shown). 
       FIGS. 20 and 21  illustrate a bracket  1300  and wire  1400  which are designed to engage each other in a secure manner so that little or no movement of the wire relative to the bracket is permitted. The bracket  1300  has first and second ends  1302 ,  1304 , a wire receiving hole  1310  and a wire engaging tongue  1311 . The wire  1400  has a loop  1402  at one end. The loop  1402  is dimensioned to be engaged by the tongue  1311  as shown in  FIG. 20 . The wire  1400  is also provided with a z-bend  1404  adjacent to the loop so that the wire may pass through the hole  1310  in the bracket  1300  as shown in  FIG. 20 . 
       FIG. 22  shows a bracket  1500  designed for use with a wire  1600  having a hooked end  1602 . As shown in  FIG. 22 , the hooked end  1602  is formed by three ninety degree bends in the wire. The bracket  1500  has a first end  1502 , a second end  1504 , and is provided with two holes  1506 ,  1508  adjacent to the second end  1504 . 
     According to one embodiment, shown in  FIG. 23 , the bottom hole  1506  is shaped like an inverted T and the top hole is a vertical slot. Those skilled in the art will appreciate that the holes and the wire are advantageously dimensioned such that it is possible to position the wire horizontally to pass through the lower horizontal par of the hole  1506 . The holes and the wire are also advantageously dimensioned such that when the wire and bracket are assembled as shown in  FIG. 22 , the lower horizontal par of the hook  1602  is engaged in the vertical portion of the inverted T slot  1506 . This arrangement restricts movement of the wire relative to the bracket. 
     According to a second embodiment, shown in  FIG. 24 , the bottom hole  1506 ′ is a horizontal slot and the upper hole  1508 ′ is substantially semi-circular. Those skilled in the art will appreciate that the wire can be hooked into the bracket following the same steps as the first embodiment. It will further be appreciated that the dimensions of the hole  1508 ′ may be chosen to allow rotation of the wire and the length of the slot  1506 ′ may be chosen to set the limits of rotational movement of the wire. Alternatively, by providing the wire with a substantially semi-circular cross section and properly dimensioning the hole  1508 ′, rotational movement of the wire relative to the bracket can be minimized or eliminated. 
       FIGS. 25-27  illustrate a bracket and wire combination which are easy to assemble and which limits movement of the wire relative to the bracket when assembled. The bracket  1600  has a straight flange  1602  coupled to a U-shaped flange  1604 . The flange  1602  has a nail receiving hole  1606  and a slot  1610  which extends into the U-shaped flange  1604 . As seen best in  FIG. 26 , the slot  1610  is T-shaped with the head of the T lying in the bottom of the U-shaped flange  1604 . 
     The wire  1700  has a T-shaped head  1702  which is dimensioned to fit through the slot  1610  and be rotated into the position shown in  FIG. 25 . As seen best in  FIG. 27 , the head  1702  of the wire  1700  is formed by six ninety degree bends in the wire resulting in the wire doubling against itself below the head. This double width fits into the head of the T-shaped slot  1610  when the wire is rotated into the position shown in  FIG. 25 . From the foregoing, those skilled in the art will appreciate that the wire and bracket are assembled by rotating the wire to the position shown in  FIG. 27  and inserting it through the slot  1610  until the double width below the head  1702  clears the slot, rotating the wire ninety degrees and lowering it to the position shown in  FIG. 25 . 
     There have been described and illustrated herein several embodiments of methods and apparatus for suspending fixtures. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as so claimed.