Patent Abstract:
A hanger assembly comprised of a longitudinal member and end brackets attached to and pivotable with respect to the member. The length of the longitudinal member is selected to span the maximum distance typically encountered with overhead joists and beams. The hanger assembly provides the advantages of being of simple construction, inexpensive, capable of spanning a wide range of distances between joists, and allowing easy squaring of junction boxes with the room in which they are installed.

Full Description:
FIELD OF THE INVENTION 
     This invention relates to hanger assemblies for suspending heavy objects such as ceiling fans, and particularly to a hanger assembly that may be easily installed to bridge the distance between two beams or joists. The hanger assembly will easily accommodate beams or joists spaced at various offsets. 
     BACKGROUND OF THE INVENTION 
     The National Electrical Code currently specifies a maximum acceptable weight of 80 pounds for ceiling light fixtures and 70 pounds for ceiling fans. It is therefore important to provide proper support for these potentially heavy devices to accommodate the static and, in the case of ceiling fans, dynamic loads that are encountered. 
     Light fixtures and ceiling fans are commonly mounted centrally on the ceiling of a room, and, in most cases, the exact center of a room does not coincide with the location of an overhead beam or joist from which to suspend the fixture. It therefore becomes necessary to provide overhead support in the exact center of the room from which to anchor the fixture or fan. Contractors typically provide overhead support by cutting a 2″×4″ header to the proper size to bridge the distance between overhead joists and then fastening it to the joists with nails or screws. 
     Typically, in new home construction, the building is framed out well before the electrical contractor arrives to install ceiling fans, light fixtures, and other electrical devices. It therefore becomes impractical and inconvenient for an electrical contractor to carry a cutting device to the work site. A need therefore exists for a device and method to easily provide overhead support for a heavy hanging object such as a light fixture or a ceiling fan. 
     For installation of light fixtures and ceiling fans in existing homes, many manufacturers produce expandable fixture support units that are inserted through the normal junction box hole in a ceiling to save the effort of creating a larger hole. A typical fixture support unit of this type is disclosed in U.S. Pat. No. 4,463,923 to Reiker (hereinafter the &#39;923 patent). This patent describes a heavy-duty expansible junction box hanger assembly adapted for installation from beneath a ceiling through a junction-box aperture in the ceiling without complete prior removal of a previously installed light-weight hanger assembly. The portion of the light-weight hanger directly above the aperture is cut away, and the heavy duty hanger is maneuvered through the aperture to a position above the light-weight hanger. A pair of feet on each end of the heavy duty hanger straddle the light-weight hanger and rest on the upper ceiling surface, aligning the heavy duty hanger parallel to the ceiling, after which joist engagement means on the hanger assembly are expanded into biting contact with the joists. 
     Although the &#39;923 patent and similar devices provide an adequate device for providing overhead support for a heavy fixture, it and similar devices have the disadvantage of being composed of a number of mechanical parts, thereby making it a complex device that is relatively expensive to manufacture. It is limited to bridging a minimum distance of 14.25″. Additionally, if the existing overhead joists are not arranged parallel to each other, no provision is made for squaring the junction box with the room. A need therefore exists for a simple, relatively inexpensive device for providing overhead support for a heavy hanging object such as a light fixture or a ceiling fan. Additionally, the device should be capable of bridging a wide range of distances between joists and allow for easy squaring of junction boxes with the room in which they are to be installed. 
     SUMMARY OF THE INVENTION 
     The present invention comprises a hanger assembly comprised of a longitudinal member and end brackets attached to and pivotable with respect to the member. The length of the longitudinal member is selected to span the maximum distance typically encountered with overhead joists and beams. The hanger assembly provides the advantages of being of simple construction, inexpensive, capable of spanning a wide range of distances between joists, and allowing easy squaring of junction boxes with the room in which they are installed. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the preferred embodiment of the hanger assembly with the longitudinal member in phantom lines and having a portion broken away. 
     FIG. 2 is a bottom view of one of the end brackets of the hanger assembly depicted in FIG.  1 . 
     FIG. 3 is a side view of one end of the hanger assembly of FIG.  1 . 
     FIG. 4 is an end view of one of the end brackets of the hanger assembly of FIG.  1 . 
     FIG. 5 is a bottom view showing the arrangement of the hanger assembly of FIG. 1 when used to span between joists spaced 24 inches apart. 
     FIG. 6 is a bottom view showing the arrangement of the hanger assembly of FIG. 1 when used to span between joists spaced 18 inches apart. 
     FIG. 7 is a bottom view showing the arrangement of the hanger assembly of FIG. 1 when used to span between joists spaced 16 inches apart. 
     FIG. 8 is a bottom view showing the arrangement of the hanger assembly of FIG. 1 when used to span between joists spaced 12 inches apart. 
     FIG. 9 is a side view depicting the hanger assembly of FIG. 1 installed between two joists and including an attached junction box and a ceiling fan. 
    
    
     INDEX TO REFERENCE NUMERALS IN DRAWINGS 
       10  hanger assembly 
       12  longitudinal member 
       14  end bracket 
       16  top (of longitudinal member) 
       18  bottom (of longitudinal member) 
       20  end flange 
       22  top flange 
       24  bottom flange 
       26  vertical tab 
       28  horizontal tab 
       30  channel 
       32  pivot pin 
       34  flathead screw 
       36  locking nut 
       38  aperture (in bottom flange) 
       40  aperture (in longitudinal member) 
       42  aperture (in top flange) 
       44  joist-accepting seat 
       46  aperture 
       48  joist 
       50  junction box 
       52  ceiling fan 
       54  ceiling 
       56  lower edge (of joist) 
       58  fastener 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG.  1  and FIG. 3, the preferred embodiment of a hanger assembly  10  according to the present invention includes a longitudinal member  12  and two end brackets  14  pivotably attached thereto. The hanger assembly  10 , when placed into use, will be oriented as shown in FIG. 1, with the reference numeral  16  referring to the top and the reference numeral  18  referring to the bottom of the longitudinal member  12 . The end brackets  14  are essentially U-shaped and consist of an end flange  20  and a top  22  and bottom  24  flange. A vertical tab  26  extends vertically from the junction of the end  20  and top  22  flange and a horizontal tab  28  extends horizontally from the junction of the end  20  and bottom  24  flange. The inside portion of the U-shaped end brackets  14  form a channel  30  capable of accepting the longitudinal member  12  therein. As shown in FIG. 3, a pivot pin  32 , consisting of a flathead screw  34  and a locking nut  36  pivotably secure end bracket  14  to longitudinal member  12  through aperture  38  in the bottom flange  24 , aperture  40  in longitudinal member  12 , and aperture  42  in top flange  22 . As shown on the far left of FIG. 3, a joist-accepting seat  44  is created on the outward surfaces of the horizontal tab  28 , end flange  20 , and vertical tab  26 . 
     Referring to FIG. 2, an end bracket  14  is shown as viewed from the bottom  18  side of the longitudinal member  12  (shown in FIG. 1) and depicts the bottom flange  24  and the end of the flathead screw  34  which, in conjunction with the locking nut (not shown), form the pivot pin  32  that will secure the longitudinal member (not shown) rotatably to each end bracket  14 . 
     FIG. 4, an end view of one of the end bracket  14  as viewed from the left side of FIG. 1, depicts the vertical tab  26  and end flange  20  both of which include apertures  46  for receipt of fasteners (not shown) for later securing the hanger assembly between overhead joists. Apertures  46  are included in the horizontal tab  28  (not shown), vertical tab  26 , and end flange  20  for the receipt of fasteners (not shown) during installation of the hanger assembly  10 . 
     For the preferred embodiment of the hanger assembly  10 , the length of the longitudinal member  12  is 21.5 inches and the end brackets  14  extend the overall length, with the end brackets  14  arranged orthogonal to the longitudinal member  12 , of the hanger assembly  10  to 22.5 inches. The length of the longitudinal member  12  could be set longer than 21.5 inches, but typically the preferred length is sufficient to span most overhead joists, which typically are spaced at 24 inches or less center to center. The preferred width of the longitudinal member is 1.5 inches and the preferred height between the top  16  and bottom  18  is 3.5 inches. 
     FIGS. 5 through 8 are bottom views of the preferred embodiment of the hanger assembly  10 , viewed from the perspective of looking upwards at the overhead joists, illustrating the arrangement of the preferred embodiment of the hanger assembly  10  when used to span between adjacent joists  48  spaced at various distances. For example, as shown in FIG. 5, when used to span between adjacent joists  48  spaced 24 inches apart center to center (c/c), the end brackets  14  are pivoted orthogonal to the longitudinal member  12  and the longitudinal member  12  therefore is orthogonal to the joists  48 . Referring to FIG. 6 as a second example, with the adjacent joists  48  spaced at 18 inches c/c, the end brackets  14  are pivoted as shown to the longitudinal member  12  and the longitudinal member  12  therefore is at an angle of approximately 45° to the joists  48 . As depicted in the third example of FIG. 7, with the adjacent joists  48  spaced at 16 inches c/c, the end brackets  14  are pivoted as shown to the longitudinal member  12  and the longitudinal member  12  therefore is at an angle of approximately 37° to the joists  48 . For a final example, as depicted in FIG. 8, with the adjacent joists  48  spaced at 12 inches c/c, the end brackets  14  are angled as shown to the longitudinal member  12  and the longitudinal member  12  therefore is at an angle of approximately 25° to the joists  48 . As suggested by the various examples depicted in FIGS. 5 through 8, the preferred embodiment of the hanger assembly  10  of the present invention can easily span a wide range of joist geometries including spans of 4.0 inches c/c to 24.0 inches c/c. Smaller or larger distances may be spanned by varying the length or width of the longitudinal member  12  from the dimensions selected for the preferred embodiment. 
     Referring to FIG. 9, a side view is shown of the preferred embodiment of the hanger assembly  10  installed between two joists  48  with an attached junction box  50  and a ceiling fan  52  secured thereto. FIG. 9 includes a ceiling  54 , typically consisting of dry wall, secured to the lower edge  56  of the joists  48 . To install a light fixture (not shown) or a ceiling fan  52  between two existing overhead joists  48 , a hanger assembly  10  is provided and the end brackets  14  are pivoted with respect to the longitudinal member  12  until the total length of the hanger assembly  10  spans the distance between the two joists  48 . The hanger assembly  10  is then inserted between the two joists  48  such that, referring to FIG. 1, the joist-accepting seat  44  of each end bracket  14  is flush against its respective joist  48 . Referring again to FIG. 9, fasteners  58  are then hammered or threaded through apertures  46  in the horizontal tab  28 , vertical tab  26 , or end flange  20  as appropriate to secure the hanger assembly  10  to the joists  48 . When secured to the joists  48 , the horizontal tab  28  is flush against the lower edge  56  of the joists  48  and therefore a ceiling  54 , typically consisting of sheet rock, may be secured to the lower edge  56  of the adjacent joists  48  and other joists in the vicinity to cover the joists. Alternatively, the hanger assembly  10  may be used to suspend a heavy object from two adjacent rafters where the rafters in the room are visible. In this case, the hanger assembly  10  would be used to provide support between two adjacent rafters and no covering material such as sheet rock would be used. 
     After the hanger assembly  10  is secured to the joists  48  with fasteners  58 , as shown in FIG. 9, an appropriate junction box  50  is secured to the hanger assembly  10  in the usual manner. The junction box  50  may be of a circular shape that is typically used with hanging light fixtures or ceiling fans or may be of the L-shaped type or of the type that contains a U-shaped channel in the top of the junction box to accommodate an overhead joist. The electrical wiring and the installation of the light fixture or ceiling fan  52  are then completed in the typical manner. 
     The preferred material of construction for the end bracket is {fraction (1/16)}″ thick pre-galvanized steel, however, it should be understood that the end brackets may be provided in various gauges without departing from the scope of the invention. The material of construction of the end brackets can also consist of various other materials such as rigid plastic, aluminum, titanium, fiberglass, etc., without departing from the scope of the invention. 
     The longitudinal member is preferably constructed from a typical piece of 2″×4″ wood such as that used for framing houses. It should be apparent that other materials, such as fiberglass, rigid plastic, steel, aluminum, or various other materials could also easily be used to construct the longitudinal member. 
     The preferred material for constructing a pivot pin is a ¼-20×4 long flathead screw and a mating lock nut. Other types, lengths, and diameters of cylindrical fasteners and locking means, or other means such as a cylindrical pin with a cotter key, may be used to connect the end brackets pivotably to the longitudinal member without departing from the scope of the invention. 
     Although the description above contains many specific descriptions, materials, and dimensions, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. 
     Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.

Technology Classification (CPC): 4