Abstract:
A universal hanger device mounts components of a heating, ventilation, and air conditioning (“HVAC”) system within an architectural structure. The universal hanger device allows HVAC components such as duct members to be mounted in any position and/or configuration.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to heat, ventilation, and air conditioning (“HVAC”) systems, and more specifically to devices used to mount components such as duct members of HVAC systems to architectural structures. 
       BACKGROUND 
       [0002]    HVAC technology is used to control indoor temperature and air flow in residential and commercial architectural structures thereby resulting in improved comfort to many clients using such systems. Due to the widespread use of HVAC systems, there is an ongoing need for improvements to such systems. 
         [0003]    A HVAC system generally connects one or more main heating and cooling units. For example, a combined furnace and condenser may be connected through the use of various HVAC components. The HVAC components are usually secured to the walls or ceilings in various positions and configurations depending on the location of air vents. 
         [0004]    A desired improvement is to increase the effectiveness and efficiency of air flow. In addition, there is a desire to improve and streamline installation of HVAC systems and related components such as duct members. For purposes of this application the term “duct member” is any shape or size tube, canal, pipe, or conduit by which a fluid, air, or other substance is conducted or conveyed. Duct members exist in a variety of constructions including various sizes and/or various shapes such as round, rectangular, flat, oval, or any combination thereof. 
         [0005]    Generally, various hanger mechanisms are used to hang components such as duct members from elements found within architectural structures. Elements found within architectural structures include, for example, support beams, ceilings, walls, joists, and studs. Conventional hanger mechanisms include one or more brackets, clamps, rods, bandings, wires, and straps. One embodiment of a conventional hanger mechanism includes an upper attachment, hanger, and lower attachment. The upper attachment secures the hanger mechanism to an element of the architectural structure and the lower attachment secures the duct member to the hanger mechanism. 
         [0006]    More specifically, a single rod hanger mechanism includes a rod secured to an element of an architectural structure. The rod attaches to a strap—otherwise referred to as “band” or “banding”—that wraps around the outside surface of the duct member. In certain embodiments, the single rod hanger mechanism may further include a clamp such as a C-clamp. The C-clamp attaches to the element of the architectural structure. One end of the rod is secured to the C-clamp and the other end of the rod attaches to the strap that wraps around the outside surface of the duct member. 
         [0007]    A double rod hanger includes two rods secured to an element of an architectural structure. Each rod attaches to a pair of semicircular bands that encircles the duct member. The rods are spaced from one another at a distance approximately equal to the diameter of the duct member. In this manner, support of the duct member is shared equally by both rods. In the embodiments described above, the banding is usually sized to match the size (diameter or width) of the duct member. 
         [0008]    One disadvantage with conventional hanger mechanisms is that they are not offered in a “one-size-fits-all”. Certain hanger mechanisms are provided in different sizes and shapes to accommodate specific size/shape duct members. Therefore, an installer must stock and have on-hand the appropriate hanger mechanisms to properly install the components of the HVAC system thereby minimizing delays and work stoppages. 
         [0009]    Another disadvantage with conventional hanger mechanisms is that they accommodate only one mounting type in terms of position and/or configuration. For example, a hanger mechanism used to mount a duct member vertically within an architectural structure cannot be used to mount a duct member horizontally. Furthermore, a hanger mechanism that mounts a duct member by supporting it from the bottom cannot be used to mount the duct member by supporting it from the top. 
         [0010]    Another disadvantage with conventional hanger mechanisms is that an installer must correctly select the hanger mechanism for installing the duct member to the architectural structure. Often times, the installer may select a certain hanger mechanism to realize that it is not the proper selection during installation. This may be particularly problematic when the installer is installing components of a HVAC system on the ceiling element of an architectural structure. Considerable time is wasted when the installer must set aside the duct member, return to the ground, obtain the correct hanger mechanism, return to the ceiling, and install the duct member. 
         [0011]    Another disadvantage is that conventional hanger mechanisms or duct members may need to change if locations for the installation of duct members change. For example, an installation planned for a ceiling requires a certain hanger mechanism and a duct member according to a certain size and/or shape. If the location for the installation changes from the ceiling to a wall, a different hanger mechanism and different sized/shaped duct member may be needed from that as originally required for the ceiling installation. 
         [0012]    Another disadvantage with conventional hanger mechanisms is that material is often times wasted. Material that is ordered and not used is usually put into stock or returned for a fee of some sort. Additionally, material that is not utilized or that is trimmed during installation may be scrapped. 
         [0013]    Improper installation of HVAC components costs clients&#39; money and reduces their comfort every time the HVAC system runs. 
         [0014]    There is a need for a hanger device that is universal such that the hanger device can be used to install duct members of any size and/or shape as well as support and/or mount duct members in any configuration. The present invention satisfies this need. 
       SUMMARY OF THE INVENTION 
       [0015]    The present invention is directed to a universal hanger device for HVAC applications. The universal hanger device according to the invention can be used with conventional hanger mechanisms such as one or more brackets, clamps, rods, bandings, wires, and straps to install duct members. The universal hanger device facilitates the installation of any size and/or shape duct members. Additionally, the universal hanger device of the invention may support the duct member from the top, bottom, or side of the duct member such that it can be mounted in any configuration—horizontal, vertical, or anywhere in between. 
         [0016]    In one embodiment, the universal hanger device includes a mounting leg component including a mounting aperture and an attachment leg component including an attachment aperture with two attachment slots, one attachment slot positioned on each side of the attachment aperture element. In one embodiment, the mounting leg component and attachment leg component are integrally formed at an angle θ, for example, ninety degrees. 
         [0017]    The universal hanger device is configured to mount a duct member using a single point application, a dual point application, or both. A single point application utilizes the attachment aperture of the attachment leg component. A dual point application utilizes the attachment slots of the attachment leg component. A single point and dual point application utilizes the attachment aperture and attachment slots of the attachment leg component. 
         [0018]    The universal hanger device is configured so that a duct member may be suspended from or secured to the universal hanger device. The point from which the duct member is suspended or secured to the universal hanger device may be different than the point at which the universal hanger device is anchored. The duct member may be mounted either parallel or perpendicular to the universal hanger device with respect to the attachment slots. 
         [0019]    The universal hanger device may be manufactured through one or more processes, for example, extrusion, injection molding, and stamping. 
         [0020]    In an embodiment where the universal hanger device is configured to mount a duct member using a single point application, a rod hanger mechanism may be used. The rod mechanism includes a rod and banding. The universal hanger device is attached to an element of an architectural structure. The rod is secured to the mounting aperture of the universal hanger device on one end and to the banding on the other end. The banding is positioned in a loop around the outside surface of the duct member. A duct member may be suspended at any distance from the universal hanger device by using a rod hanger mechanism and length of banding desired. 
         [0021]    In another embodiment where the universal hanger device is configured to mount a duct member using both a single point application and dual point application, the rod hanger mechanism may further include a clamp such as a C-clamp. The C-clamp attaches to the element of the architectural structure. One end of the rod is secured to the C-clamp and the other end of the rod attaches to the universal hanger device. A strap wraps around the outside surface of the duct member and attaches to the attachment slots of the universal hanger device. 
         [0022]    In an embodiment where the universal hanger device is configured to mount a duct member using a dual point application, a strap mechanism is used. The strap mechanism includes a band or banding. The universal hanger device is attached to an element of an architectural structure. The banding is routed within the slots of the universal hanger device and positioned around the outside surface of the duct member. 
         [0023]    One advantage of the present invention is that banding may be purchased in bulk for use with the universal hanger device. More specifically, a roll of banding may be purchased so that an installer may cut bands to any desired length in order to create any size loop that accommodates the outside surface of a duct member. For example, an installer may cut a band of a certain length from the roll to create a loop for a 4 foot diameter duct member. The band is then used with the universal hanger device in either the single point application, dual point application, or both. The universal hanger device facilitates the use of any size banding, which eliminates the need for the installer to have on-hand a specific size band. 
         [0024]    Furthermore, scrap material may be used. For example, it is contemplated that scrap sheet metal may be used to make banding. This is extremely advantageous in that material may be recycled thereby reducing waste. Furthermore, utilizing scrap material for use with the universal hanger device eliminates the need for specific size banding such that the installer does not have to have every variety of banding on-hand. 
         [0025]    The universal hanger device provides an improvement over conventional devices. Specifically, any size and/or shape duct member may be mounted by using the universal hanger device of the present invention. Additionally, the duct member may be mounted in any configuration—horizontal, vertical, or anywhere in between. The universal hanger device eliminates the need for size specific conventional hanger mechanisms. The universal hanger device also eliminates the requirement for installers to select conventional hanger mechanisms based upon the size/shape duct member and the architectural structure to which the duct member is to be mounted. The universal hanger device minimizes delays and work stoppages. 
         [0026]    The described embodiments are to be considered in all respects only as illustrative and not restrictive, and the scope of the invention is not limited to the foregoing description. Those of skill in the art will recognize changes, substitutions and other modifications that will nonetheless come within the scope of the invention and range of the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    The preferred embodiments of the invention will be described in conjunction with the appended drawings provided to illustrate and not to the limit the invention, where like designations denote like elements, and in which: 
           [0028]      FIG. 1A  illustrates a perspective view of a universal hanger device according to one embodiment of the invention; 
           [0029]      FIG. 1B  illustrates another perspective view of the universal hanger device according to one embodiment of the invention; 
           [0030]      FIG. 2A  illustrates the universal hanger device used in mounting a duct member according to one embodiment of the invention; 
           [0031]      FIG. 2B  illustrates the universal hanger device used in mounting a duct member according to another embodiment of the invention; 
           [0032]      FIG. 2C  illustrates the universal hanger device used in mounting a duct member according to another embodiment of the invention; 
           [0033]      FIG. 2D  illustrates the universal hanger device used in mounting a duct member according to another embodiment of the invention; 
           [0034]      FIG. 2E  illustrates the universal hanger device used in mounting a duct member according to another embodiment of the invention; 
           [0035]      FIG. 2F  illustrates the universal hanger device used in mounting a duct member according to another embodiment of the invention; 
           [0036]      FIG. 2G  illustrates the universal hanger device used in mounting a duct member according to another embodiment of the invention; and 
           [0037]      FIG. 2H  illustrates the universal hanger device used in mounting a duct member according to another embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0038]    The present invention is directed to a universal hanger device for HVAC applications. Specifically, the universal hanger device of the invention may support a duct member from the top, bottom, or side of the duct member such that it can be mounted in any configuration—horizontal, vertical, or anywhere in between. The universal hanger device mounts any size and/or shape duct member. The universal hanger device is configured so that a duct member may be suspended from or secured to the universal hanger device. A duct member may be suspended at any distance from the universal hanger device by using a rod hanger mechanism. A duct member may be secured to the universal hanger device by using a band hanger mechanism. The point from which the duct member is suspended or secured may be different than the point at which the universal hanger device is anchored. 
         [0039]    As shown in  FIG. 1A  and  FIG. 1B , the universal hanger device  50  includes a mounting leg component  100  and an attachment leg component  200 . The mounting leg component  100  and the attachment leg component  200  are integrally formed at an angle θ. As best seen in  FIG. 1A , the mounting leg component  100  and attachment leg component  200  are integrally formed at approximately a 90 degree angle θ. However, it is contemplated that angle θ may be any degree angle—acute or obtuse. 
         [0040]    The universal hanger device  50  may be made from any material, including but not limited to, steel, aluminum, plastic, and metallic alloys. It is contemplated that the universal hanger device  50  is made of a material with sufficient strength to support duct members when mounted. It is also contemplated that the material may be galvanized to reduce or prevent corrosion. It is further contemplated that the material may be paintable in order to match elements of the architectural structure to which the universal hanger device is mounted. 
         [0041]    The mounting leg component  100  is defined by walls  101 ,  102 ,  103 ,  104 ,  105 . As best shown in  FIG. 1B , walls  102 ,  104  are truncated. The truncated walls,  102 ,  104  accommodate any space constraints that may be encountered when anchoring the universal hanger device to an element of an architectural structure. Although the universal hanger device  50  is illustrated with five walls  101 ,  102 ,  103 ,  104 , and  105 , it is contemplated the mounting leg component  100  may be defined by three walls—without truncated walls. 
         [0042]    The mounting leg component  100  includes a mounting aperture element  120  defined by surface  121 . Surface  121  includes a circular portion  122  and an oval portion  123 . As seen in  FIG. 1B , the diameter “D” of the circular portion  122  is greater than the diameter “d” of the oval portion  123 . The portions  122 ,  123  of the mounting aperture element  120  accommodate different hardware members (i.e., different sizes) as well as facilitate different anchor location points for the universal hanger device  50 . As shown in  FIG. 1B , the mounting aperture element  120  is generally centered between the truncated walls  102 ,  104 . 
         [0043]    The attachment leg component  200  is defined by walls  201 ,  202 ,  203  and includes an attachment aperture element  220  and attachment slot elements  240 A,  240 B. The attachment aperture element  220  is defined by surface  221 . Surface  221  includes a circular portion  222 . The attachment aperture element  220  accommodates a rod hanger mechanism used to suspend a duct member at any distance from the universal hanger device  50 . As shown in  FIG. 1B , the attachment aperture element  220  is generally centered between walls  201 ,  203 . 
         [0044]    Attachment slot elements  240 A,  240 B are defined by surfaces  241 A,  241 B. Surface  241 A includes two linear portions  242 A,  242 AA and two circular portions  243 A,  243 AA. Surface  241 B includes two linear portions  242 B,  242 BB and two circular portions  243 B,  243 BB. Preferably, the attachment slot elements  240 A,  240 B are parallel to one another and are positioned on each side of the attachment aperture element  220 . Specifically, each attachment slot element  240 A,  240 B are positioned between the attachment aperture element  220  and walls  201 ,  203 , respectively. The attachment slot elements  240 A,  240 B accommodate a band hanger mechanism used to secure a duct member to the universal hanger device  50 . 
         [0045]    As best seen in  FIG. 1B , the walls  201 ,  203  of the attachment leg component  200  include a chamfer edge  244 A,  244 B. Similarly, the linear portions  242 A,  242 B of the attachment slot elements  240 A,  240 B include a chamfer edge  244 C,  244 D, respectively. The chamfer edges  244 A,  244 B,  244 C,  244 D may be at any angle with respect to the attachment leg component  200 . For example, the chamfer edges  244 A,  244 B may be at any angle with respect to the walls  201 ,  203  and chamfer edges  244 C,  244 D may be at any angle with respect to surfaces  241 A,  241 B of the attachment slot elements  240 A,  240 B. The chamfer edges  244 A,  244 B,  244 C,  244 D prevent damage to banding when positioned near walls  201 ,  203  of the attachment leg component  200  and near linear portions  242 A,  242 B of the attachment slot elements  240 A,  240 B when securing a duct member. 
         [0046]    In one embodiment, the chamfer edge  244 A of the wall  201  of the attachment leg component  200  is at approximately a forty-five degree angle and the chamfer edge  244 C of the linear portion  242 A is at approximately a forty-five degree angle so that chamfer edges  244 A,  244 C are configured to reside in planes that are perpendicular to one another. Likewise, the chamfer edge  244 B of the wall  201  is at approximately a forty-five degree angle and the chamfer edge  244 D of the linear portion  242 B is at approximately a forty-five degree angle so that chamfer edges  244 B,  244 D are configured to reside in planes that are perpendicular to one another. In other words, in this embodiment, chamfer edges  244 A,  244 D reside in planes that are parallel to one another, and similarly, chamfer edges  244 B,  244 C reside in planes that are parallel to one another. Although the chamfer edges are described in one embodiment as being at approximately forty-five degree angles, any angle is contemplated. 
         [0047]      FIG. 2A  and  FIG. 2B  illustrate embodiments in which the universal hanger device  50  is configured to mount a duct member  70  using a single point application. Specifically, the single point application uses a rod hanger mechanism  300  including a rod  302  and a band  304 . The universal hanger device  50  is attached to an element  60  of an architectural structure. Specifically, the mounting aperture element  120  of the mounting leg component  100  receives hardware  91  such as a screw to attach the universal hanger device  50  to the element  60 . Using hardware  92  such as a bolted joint, the rod  302  is secured at one end to the attachment aperture element  220  of the attachment leg component  200 . In one embodiment the attachment aperture element  220  is 7/16 inch to accommodate a ⅜ inch diameter rod. The other end of the rod  302  is secured to band  304  using hardware  93  such as a bolted joint. The band  304  is positioned in a loop around the outside surface of the duct member  70 . The duct member  70  may be suspended at any distance from the universal hanger device  50  by using a rod hanger mechanism  300 . As shown, the universal hanger device  50  used with a rod hanger mechanism  300  allows the duct member  70  to be configured horizontally with respect to the element  60  of the architectural structure. Although the duct member  70  is shown as circular in cross-sectional shape in  FIG. 2A  and  FIG. 2B , it is contemplated that the duct member may also be square or rectangular in cross-sectional shape. Furthermore, it is contemplated that a double rod hanger could be used. A double rod hanger includes two rods secured to an element of an architectural structure. Each rod attaches to the attachment slot elements  240 A,  240 B and a pair of semicircular bands loops around the outside surface of the duct member. 
         [0048]      FIG. 2C  and  FIG. 2D  illustrate both a single point application and dual point application in which the rod hanger mechanism  300  includes a C-clamp  301 , rod  302 , and a band  304 . The C-clamp  301  grabs the element  60  of the architectural structure. One end of the rod  302  attaches to the C-clamp  301  using hardware  94  such as a bolted joint. The other end of the rod  302  passes through the attachment aperture element  220  of the universal hanger device  50  and is secured using hardware  95  such as a bolted joint. Banding  304  is routed within the attachment slot elements  240 A,  240 B of the universal hanger device  50  and positioned in a loop around the outside surface of the duct member  70 . 
         [0049]    In the embodiment shown in  FIG. 2C , the ends  304 A of the banding  302  are routed over walls  201 ,  203  including chamfer edges  244 A,  244 B, respectively, and through attachment slot elements  240 A,  240 B including chamfer edge  244 C,  244 D, respectively (see  FIG. 1A  and  FIG. 1B ). The ends  304 A are secured to the banding  302  by hardware  96  such as screws. This arrangement is aesthetically pleasing since the ends  304 A cannot be seen by being positioned between the duct member  70  and banding  304 . 
         [0050]    In the embodiment shown in  FIG. 2D , the ends  304 B of the banding  302  are routed through attachment slot elements  240 A,  240 B including chamfer edge  244 C,  244 D, respectively and over walls  201 ,  203  including chamfer edges  244 A,  244 B, respectively (see  FIG. 1A  and  FIG. 1B ). The ends  304 B are secured to the banding  302  by hardware  96  such as screws. This arrangement may be used when aesthetics is unimportant since the ends  304 B can be seen by being positioned outside the duct member  70  and banding  304 . 
         [0051]      FIG. 2E ,  FIG. 2F ,  FIG. 2G , and  FIG. 2H  illustrate embodiments in which the universal hanger device  50  is configured to mount a duct member  70  using a dual point application. Specifically, the dual point application uses a strap mechanism  400  including band  402 . The universal hanger device  50  is attached to an element  60  of an architectural structure. Specifically, the mounting aperture element  120  of the mounting leg component  100  receives hardware  97  such as screws to attach the universal hanger device  50  to the element  60 . The band  402  is routed within the attachment slot elements  240 A,  240 B of the universal hanger device  50  and positioned in a loop around the outside surface of the duct member  70 . In one embodiment, the attachment slot elements are 1⅛″ inches in length in order to receive band having a  1  inch width. 
         [0052]    Specifically, the band  402  is routed through the attachment slot element  240 A such that the band  402  rests over chamfer edge  244 A and chamfer edge  244 C. Similarly, the band  402  is routed through the attachment slot element  240 B such that the band  402  rests over chamfer edge  244 B and chamfer edge  244 D. The ends of the band  402  may be secured to itself, to the universal hanger device  50 , or to another fixed object such as an element of the architectural structure. 
         [0053]    As shown in  FIG. 2E ,  FIG. 2F ,  FIG. 2G , and  FIG. 2H , the duct member  70  may be secured parallel or perpendicular to the universal hanger device  50  with respect to the attachment slot elements  240 A,  240 B and configured horizontally or vertically with respect to the element  60  of the architectural structure. Again, although the duct member  70  is shown as circular in cross-sectional shape in  FIG. 2E ,  FIG. 2F ,  FIG. 2G , and  FIG. 2H , it is contemplated that the duct member may also be square or rectangular in cross-sectional shape. 
         [0054]    While the present invention has been described with reference to particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the scope of the present invention. Each of these embodiments and variants thereof is contemplated as falling with the scope of the claimed invention, as set forth in the following claims.