Abstract:
A method and apparatus is provided for suspending a strut rack assembly from one or more vertical threaded rods without passing the assembly over the ends of the rods utilizing a snap off one piece nut that includes two portions which are substantially planar structures. Each portion includes an open aperture across the planar structure leading to a threaded portion. One of the portions includes a sliding guide tray which is designed to receive the other portion and includes a screw hole. The other portion includes an inclined surface designed to interact with a screw member provided through the screw hole. In essence, the screw member pushes forward the inclined surface of the other portion so that the threaded portions of the front and second portions tighten around a threaded rod.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Application No. 60/848,709, filed Oct. 2, 2006. 
     
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to suspended strut members and support thereof, and more particularly to a method and apparatus for suspending extra strut members from threaded rod that has other strut members already suspended from the strut rod, without removing the existing strut members. 
       BACKGROUND OF THE INVENTION 
       [0003]    In architectural settings, it is often necessary to improve architectural structures by adding, changing or removing certain portions. Such architectural improvements and additions are constantly being made in commercial and industrial settings. More specifically, in many commercial and industrial settings, changes need to be made in modular, steel, aluminum, and fiberglass reinforced plastic framing products and accessories suitable for electrical, industrial, construction and other applications without welding or performing other permanent changes. One of the common problems encountered in changing the modular form of the architectural construction is the removal or addition of horizontal members to the existing threaded rod assemblies. To effectively add or remove horizontal members to existing threaded rod assemblies, such procedure requires the whole assembly to be removed and a new assembly to be installed. Then, the original assembly will be reinstalled, which is very labor intensive, and adds a substantial cost to a work project. 
         [0004]    A strut system is a system of horizontally placed channeled strut members suspended from the ceiling on a plurality of vertical threaded rods. The channel strut member has a plurality of holes through which the vertical rods are received as the strut member is raised to the proper elevation. A washer and a threaded nut are run up on the rod to engage the bottom of the strut member or the top of the strut member and support the strut member on the rod. Pipes or electrical cables are supported horizontally on these pipe rack strut members and run horizontally overhead throughout the building. 
         [0005]    When architectural improvements, additions or removals require new pipe or electrical hookups, or rerouting, the suspended pipes or electrical cables must be removed or replaced, or new ones added. This procedure often requires expensive periods of shutdowns while the pipe racks are disassembled. In some cases, a second layer or intermediate pipe rack may be installed above the existing one to allow placement of the new pipe or cable before the old ones are removed. 
         [0006]    For instance, to install an intermediate pipe rack above an existing one, it is necessary to remove the old strut members from the vertical threaded rod, or to take off the nut and lower the strut members. The intermediate strut member must then be forced over the existing pipe and cable which often requires bending or cutting an existing support rod to allow the intermediate strut member to fit on the rods above the pipe and cable. Then the old lower strut member must be put back into position. This threading procedure alone takes many hours. 
         [0007]    One solution has been to provide a split nut device, which can be assembled onsite to support strut members. Various split nut configurations, although not utilized to support strut members, are known in the art. Specifically, there are several patents directed to various split nut configurations. 
         [0008]    For instance, U.S. Pat. No. 5,039,266 to Nagayoshi et al. discloses on  FIG. 11 , a pair of divided nut parts connected by bendable connectors. As can be seen, such device is not suited for supporting a strut member, thereon. 
         [0009]    Thus, a simple to manufacture device which is easy to install on a threaded rod with existing strut members without the necessity of removing any members already in place, utilizing channels and trapeze in the suspending hangers is desired. 
       SUMMARY OF THE INVENTION 
       [0010]    The present invention provides an apparatus for suspending a strut rack assembly from one or more threaded rods without passing the assembly over the end of the shafts. The apparatus includes a substantially planar monolithic body with a top surface, a bottom surface and side edges thereof, and including a receptacle portion preformed with at least a defined narrow joint linked to a detachable slider portion configured to detach and slide into the receptacle portion, the joint defining two access openings extending to an internally threaded portion of the receptacle portion and the slider portion for insertable accommodation of the threaded rod. 
         [0011]    Further, the present invention also provides for a hanger nut assembly wherein the receptacle portion has a substantially rectangular perimeter with a pair of raised side edges, each forming a narrow longitudinal upper ridge having a proximate end and a distal end, the distal end curving inwardly to define an angled bend forming a retaining sliding mechanism of a guide tray for accommodating the slider portion. 
         [0012]    Additionally, the present invention further provides for a hanger nut assembly including a screw, wherein the proximate end of the longitudinal upper ridge includes a threaded hole to accommodate the screw and a corner of the slider portion includes a slanted surface on a ledge adapted to cooperate with the screw and move the slider portion toward the receptacle portion and clamp around the threaded rod as the tip of the screw presses along the slanted surface. 
         [0013]    A still further embodiment of the invention provides for a hanger nut assembly wherein the joint is formed with a specified tensile strength to maintain connection of the slider portion with the receptacle portion during transportation and to easily to snap off and detach by hand. 
         [0014]    The present invention also provides for a hanger nut assembly wherein a captive screw is provided in the threaded hole so as to prevent disengagement from said body. 
         [0015]    The present invention further provides for a method of supporting a strut having a threaded rod extending therethrough, by providing a preformed substantially planar monolithic body including a receptacle portion and a slider portion joined at a pair of linking joints, the linking joints defining two access openings extending to an internally threaded portion of the receptacle portion and the slider portion for insertable accommodation of the threaded rod, snapping the slider portion off from the receptacle portion, wherein the receptacle portion includes a pair of upper ridge with a bend forming a retaining sliding mechanism of a guide tray for accommodating said slider portion and a threaded hole, guiding the internally threaded portion of the receptacle portion around the threaded rod, guiding the internally threaded portion of the slider portion into the guide tray of the receptacle portion, wherein a corner the slider portion includes a slanted surface adapted to cooperate with the screw and drive the slider portion toward the receptacle portion to clamp around the threaded rod, turning the screw through the screw hole and against the slanted surface to hold the receptacle portion and the slider portion together against the threaded rod, moving the receptacle portion up or down on the threaded rod to a desired position, tightening the screw to securely clamp the receptacle portion and the slider portion together on the threaded rod, and placing a strut member against the body and preferably against a bottom surface of said receptacle portion. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  is a perspective view of a preferred embodiment of the present invention; 
           [0017]      FIG. 2  is a bottom plan view showing the bottom side of the embodiment as shown in  FIG. 1 ; 
           [0018]      FIG. 3  is a side plan view showing the distal end of the embodiment shown in  FIG. 1 ; 
           [0019]      FIG. 4  is a perspective view of the embodiment as shown in  FIG. 1 , wherein the slider portion is being snapped off from the receptacle portion as part of a preferred method of installation; 
           [0020]      FIG. 5  is a perspective view of the embodiment as shown in  FIG. 1 , shows the receptacle portion and the slider portion conjoining together around a threaded support rod as a further step of the preferred method initially shown in  FIG. 4 ; 
           [0021]      FIG. 6  is a perspective view of the preferred embodiment shown in  FIG. 1 , disclosing a further step of the preferred method as shown in  FIGS. 4 and 5 , with a screw forcing the slider portion to tighten around the threaded rod together with the receptacle portion; 
           [0022]      FIG. 7  is a bottom plan view showing another embodiment of the present invention with a different linking joint location; 
           [0023]      FIG. 8  is a bottom plan view showing further another embodiment of the present invention with a different linking joint location; 
           [0024]      FIG. 9  is a top plan view showing another embodiment of the present invention with a pair of top bent ridges; 
           [0025]      FIG. 10  is a end view showing another embodiment of the present invention with a snap-on ridges feature; and 
           [0026]      FIG. 11  is a side plan view of another embodiment of the present invention with grooves and ridges on the ledge portion. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0027]    The monolithically fabricated body  102  includes two portions, a substantially rectangular receptacle portion  400  and a similarly profiled detachable slider portion  300  conjoined by a narrow linking joint  350  and  352 . The receptacle portion  400  serves as a guide tray and receives the detachable slider portion  300 , thereby forming a nut around a threaded rod  98  positioned between the two engaging portions. 
         [0028]    The present invention will be described with reference to the sliding nut assembly shown in the drawings presented here with, but is not limited to this particular embodiment. It is contemplated that a sliding nut assembly within the scope of the present invention can be constructed with various different configurations to receive a threaded support rod. It is further contemplated that the present invention may be utilized in other areas not related to the architectural setting of suspended strut rack installations as described above. 
         [0029]    Referring now to the  FIGS. 1 and 2 , a snap-off sliding nut assembly  100  of the present invention is shown. Sliding nut assembly  100  includes a monolithically prefabricated body  102 , which may be utilized in a previously installed suspended strut rack installation without removing any of its members. The sliding nut assembly  100  is manufactured with two distinct portions, the substantially rectangular receptacle portion  400  and the similarly shaped slider portion  300 . The receptacle portion  400  is frangible attached to the slider portion  300  at fragile linking joints  350  and  352  located on either side of opening  460  defined by both portions  400  and  300 . Opening  460  may be elliptical, oblong, or some other shape. 
         [0030]    The slider portion  300  is substantially planar and rectangular in shape, and includes perimetrical side edges including two-sided surfaces  310 ,  320 , and a distal edge surface  330  which is formed away from the proximate position at the conjoined linking joints  350 ,  352  which serve as breaking points. 
         [0031]    The receptacle portion  400  also includes perimetrical side edges  410 , and  420  with a distal edge surface  423 . The two side surfaces  410 , and  420 , located at the outer perimeter of the receptacle portion  400 , curvilinearly extend from the surface of portion  400  perpendicular to the axis  150 , and parallel to the axis  152 . The raised side surfaces  410 , and  420 , thus formed, provide a set of upper raised longitudinal guide ridges  412 , and  422  at either sides of the main receptacle body  402 . The width of the main body  402 , as defined by the boundary of the guide ridges  412  and  422  at either ends, is slightly wider than the width of the slider portion  300 . Therefore, when the slider portion  300  is detached from the receptacle portion  400  at frangible linking joints  350  and  352 , the slider portion  300  can be accommodated between the set of raised longitudinal guide ridges  412 ,  422 . In addition, the rectangular perimeter of the receptacle portion  400  can serve to abut against other architectural members and the monolithic planar nut body  402  can provide a handle-friendly surface. 
         [0032]    As mentioned above, the receptacle portion  400  and the slider portion  300  are attached at frangible linking joints  350  and  352 . The linking joints  350 ,  352  are formed with a specified tensile strength to maintain connection of the slider portion  300  with the receptacle portion  400  during transportation and also an easy to snap off narrow connection feature, which allow the receptacle portion  400  and the slider portion  300  to break off from each other by hand. 
         [0033]      FIG. 1  also shows that the raised guide ridges  412  and  422 , are not fully attached to the main body  402  along its longitudinal length. Instead, the distal portions  414 ,  424  of the raised guide ridges  412 ,  422  are separated from the main body  402  with a spacing  425  having a defined distance. Further, the distal portions  414  and  424  are bent inwardly toward each other to define an angled bend, thus creating a vertical guide for the slider portion  300 . In essence, the thickness of the spacing  425  is at least greater than the thickness of the slider portion  300  such that the distal portions  414 ,  424  guide and retain the slider portion  300  from separating in the axis  152  direction away from the receptacle portion  400 . 
         [0034]    The proximate portion  416  of the raised guide ridge  412  includes a threaded hole  430  therethrough. This threaded hole  430  accommodates a screw  120 , together forming tightening fastener sub-assembly in combination with the slider portion  300 . Thus, the retaining slider mechanism, in effect, also functions as a part of the tightening fastener sub-assembly. 
         [0035]    As can be seen in  FIG. 2 , the monolithic assembly body  402  includes an elongated inner opening  460  with the hole extended along axis  150  and defined with the aperture entries  354 ,  356  at the linking joints  350 ,  352 . When the slider portion  300  is detached from the receptacle portion  400 , the opening  460  extends from the aperture entries  354  and  356  at the linking joints  350 ,  352  along a pair of guide surfaces  358 , and  360  into an internally threaded portion  362 . As can be noted, the guide surfaces  358  and  360  are slightly wider than the internally threaded portion  362  to easily accommodate a threaded rod  98 . Equally, at the receptacle portion  400 , the elliptical opening  460  extends from the aperture entries  454 ,  456  located at the linking joints  350 ,  352  and runs along a pair of guide surfaces  458  and  461  and finally terminates into an internally threaded portion  462  to accommodate the threaded rod  98  in cooperation with the internally threaded portion  362  of the slider portion  300 . 
         [0036]    As can be seen in  FIGS. 1 ,  3 ,  5  and  6 , a ledge  440  is provided at one corner of the distal portion  330  with a substantially horizontal surface  442  and a vertical slanted surface  444 . As can be readily seen in  FIG. 6 , this inclined corner ledge  440  is designed with a specific degree to interact with the screw  120 . The specified degree corresponds to the length of the screw  120  such that as the screw  120  is tightened against the threaded hole  430  in the proximate portion  416 , the tip of the screw  120  presses against the vertical angle wall surface  444 , thereby sliding the slider portion  300  further into the receptacle portion  400  to firmly clasp the threaded rod  98 . Thus, as the slider portion  300  tightens around the threaded rod  98 , a tight support for the strut member (not shown) is accomplished. Preferably, the substantially horizontal surface also includes an incline or a set of graduated steps adapted to cooperate against the threads of the screw  120  and secure the slider portion  300 . 
         [0037]    In a preferred embodiment, the screw is provided as a captive screw provided in the threaded hole  430 , so as to not fall off of the body  402 . In addition, preferably, the screw  120  provides for a tightening fastener sub-assembly configured for disassembly and reuse of the hanger nut assembly. 
         [0038]    The captive screw may also include split washers clipped on after the screw has been inserted in the panel, threaded panel holes used in conjunction with a screw that has an externally relieved shank, a long groove between the head and threads, or a ferrule or sleeve that is pressed, threaded, swaged, or flared to the parent material. 
         [0039]    Having described the physical attributes of the sliding nut assembly  100 , a preferred installation method of the sliding nut in a strut assembly shall be described in detail by referring to  FIGS. 4 ,  5  and  6 .  FIG. 4  shows the preformed sliding nut assembly with the screw  120  already installed in the body  102 . Initially, an installer snaps off the slider portion  300  from the receptacle portion  400  at the breaking point of linking joints  350 ,  352  so that the body  102  becomes two separate parts, the receptacle portion  400  and the slider portion  300 . 
         [0040]    Next, as seen in  FIG. 5 , the wide aperture entries  454 ,  456  of the rectangular receptacle portion  400  is placed around and accommodates the vertical shaft of the threaded rod  98 . Optionally, the hanger nut assembly  100  may be installed upside down such that the bottom surface provides an abutting support body against a strut member. The installer then inserts the slider portion  300  toward the threaded rod  98  guided by the upper guide ridges  412  and  422  and the angled bend in a sliding mechanism. In other words, as these two separate portions  300  and  400  are combined together onto a threaded rod as shown in  FIG. 6 , the pair of tongues  370  and  372  of the slider portion  300  run along the upper side surface of the receptacle portion  400 , between the guide ridges  412  and  422  and underneath the angled bends. 
         [0041]    The installer further slides the slider portion  300  further into the receptacle portion  400  until the ledge  440  passes over the screw tip  122 . Once the ledge  440  passes into the screw tip  122 , the installer, then tightens the screw  120  further into the threaded hole  430 , the tip  122  of the screw, pressing against the vertical surface  444  of the ledge  440 , urging the slider portion  300  further toward the receptacle portion  400  and the shaft of the threaded rod  98 . As the screw  120  is tightened further, the internal threaded portions  362  and  462  tighten around the shaft of the threaded rod  98 . 
         [0042]    Next, as the sliding nut assembly  100  is substantially tightened around the threaded rod  98 , the sliding nut assembly  100  is rotatably moved up or down to a preferred position. If necessary, the sliding nut assembly  100  may be slightly repositioned along the shaft of the threaded rod  98  such that the whole assembly is aligned with the top wall of the strut. The sliding nut assembly  100  may be turned by hand or with a wrench to adjust the position to a level of the assembled strut member at the proper height. Then, the installer further tightens the screw  120  into the threaded hole  430  to firmly clamp the sliding nut assembly  100  in a threaded engagement with the threaded rod  98 . This final step is shown in  FIG. 6  wherein the screw  120  is tightened so that the end point tip  122  of the screw pushes the surface  444  so that the slider portion  300  is forcibly directed toward the threaded rod  98 , ensuring that the slider portion  300  and the receptacle portion  400  are not separated. The sliding nut assembly  100 , then can receive a strut member on top or the sliding nut assembly  100  can be lowered against the upper portion of the strut member. In this manner, the strut member cannot move up or down on the threaded rod  98 , thus providing for support thereof. 
         [0043]    The above method is then repeated to install additional strut assemblies on all the threaded rods to form a plurality of generally parallel strut assemblies capable of receiving and supporting pipes, cables, and the like thereon. 
         [0044]    Once the sliding nut assembly  100  is positioned by a hand or a wrench, the steps are repeated to install additional slot assemblies on all the shafts to form a plurality of generally parallel sliding nut assemblies capable of receiving and supporting pipes, cables, and the like thereon. 
         [0045]    To remove the cable strut assembly, the sliding nut assembly  100  can be quickly removed by untightening the screw  120  from the sliding nut assembly  100 , and slidably retracting the slider portion  300  away from the receptacle portion  400 , allowing the assembled struts to slide off the threaded rod  98 . 
         [0046]    The above described apparatus and method provides for a sliding nut assembly with a strut rack system which may be installed as original equipment to become the primary strut rack or maybe even be quickly installed as an intermediate or upper rack above existing strut racks without the necessity of removing any members already in place. 
         [0047]    The sliding nut assembly  100 , manufactured as described above, can be produced from metal, hardened plastic, or elastomer. Further, such sliding nut assembly can be manufactured by different processes, extrusions, machining, or stamping or combinations of any previously described processes. 
         [0048]    Additionally, different types of monolithic body may be manufactured according to the present invention.  FIGS. 7 and 8  show variations of the monolithic nut assembly body  600  and  700  respectively, where the linking joints  750 ,  850  respectively are shown at different locations on the body. In essence, the joint is provided at side edges away from the access openings. 
         [0049]    Further, different types of guiding member may be produced according to the present invention. Specifically,  FIGS. 9 and 10  show different embodiments of the sliding nut assembly.  FIG. 9  shows the ridge portions which have been raised from the main body, and then, bent toward each other at angles parallel to the axis  150 . As can be noted, the ridge portion  916  is left intact and includes a threaded hole  930  to accommodate a screw  120 . Thus, guide members  912  and  922  also provide for a surface to abut architectural structures against, such as the strut members. 
         [0050]      FIG. 10  shows ridge portions defining a narrower width than the width of the sliding member  1030 . Thus fabricated, the slider portion  1030  can be snapped onto the receptacle portion in between the ridge portions  1012  and  1022  instead of sliding in between the portions  1012  and  1022 . Thus, the receptacle portion accommodates the slider portion  1030  in a snap-on configuration. 
         [0051]    Further, other additional features are envisioned by the present invention. For instance,  FIG. 11  shows the incline portion of the slider portion  1130 , wherein the incline is further accented by grooves and peaks  1140 . These grooves and peaks  1140  correspond to the threads of the screw member  120  as the screw is twisted into the slider portion  300 . Thus, the thread members of the distal portion  122  of screw  120  interacts with the grooves and peaks  1140  on the ledge to provide for a more secure receptacle-slider portion combination. 
         [0052]    A different type of tightening fastener sub-assembly is envisioned wherein a third clasping member may be provided to clasp the receptacle portion and the slider portion or a clip or other types thereof. 
         [0053]    It should be understood that other types of fasteners other than the sliding nut may be used to secure the sliding nut members together. For example, a bolt or a nail may be used instead of a screw. 
         [0054]    The particular preferred disclosed embodiments and practices are intended in a descriptive sense and are not limiting. The scope of the invention is set forth in the following claims.