BAR HANGER WITH IDENTICAL MEMBERS FOR RECESSED LUMINAIRES
A bar hanger member is provided. The bar hanger member is for assembling with another like-member by superposition thereon to form a bar hanger for supporting recessed luminaires. The bar hanger member includes: an elongated body having a front face and a rear face; a channel extending through the body along the lengthwise axis; and first and second protrusions extending from the body aligned with the channel. The first and second protrusions are sized and shaped for slidable engagement with the channel of the like-member. When the bar hanger is assembled with the like-member, the second protrusion of the bar hanger engages in the channel of the like-member and the first protrusion of the like-member engages in the channel of the bar hanger member.
This application claims priority from U.S. patent application Ser. No. 15/489,878, filed on Apr. 18, 2017, the content of which is incorporated herein by reference in its entirety.
TECHNICAL FIELDThe technical field generally relates to bar hangers. More specifically, it relates to length-adjustable bar hangers for supporting recessed luminaires.
BACKGROUNDRecessed lighting fixtures are commonly held up in ceilings prior to installation of the ceiling panel by way of two bars, commonly known as bar hangers. These are sometimes adjustable in length, and have means to attach or locate on ceiling joists and/or suspended ceiling grid systems such as T-bars.
In one design, the bar hanger consists of a male member which slides within a female member, allowing the overall length to vary depending on ceiling requirements. Locking the members together is often achieved by way of a locking screw, and the desired distance of the overall bar hanger is typically only achieved once the recessed light fixture assembly is raised up to the ceiling.
Current bar hanger systems have several limitations. Generally, two different members are required (e.g. one male and one female), thus requiring one of each of member to assemble a bar hanger. Moreover, the tightening of a fastener is often required to lock an extension, requiring a specific tool, e.g. screwdriver, wrench, or bit, which can also only be accessed from a specific orientation of the tool. Further, existing locking systems can leave unwanted play and reduced rigidity, and greater deflection under load. Additionally, there is no way to extend the bar hangers to pre-set distances without using a tape measure or other external measuring device. Finally, esiting bar hangers have limited spans, either finite, or only extendable beyond a primary lmit with a separate extension element.
SUMMARYIt is therefore an object of the present disclosure to overcome at least some of the shortcoming of the prior art.
According to an aspect, a bar hanger member is provided. The bar hanger member is for assembling with another identical bar hanger member to form a bar hanger for supporting recessed luminaires. The bar hanger member has a unitary body including: an elongated section extending along a lengthwise axis between first and second ends, the elongated section having an L-shaped profile with a front face and a rear face; a channel extending through the elongated section along the lengthwise axis, and opening on the front and rear faces, the channel including first and second slots proximate to the first end for receiving correspondingly shaped protrusions therethrough; first and second protrusions extending from the elongated section proximate to the first end and aligned with the channel along the lengthwise axis, the first and second protrusions being shaped to fit through the first and second slots and slide along the channel, the first protrusion extending from the front face of the elongated section, and the second protrusion extending from the rear face of the elongated section; and a mounting plate extending from the second end for securing the bar hanger member to a joist. The bar hanger is assembled with the identical bar hanger member to form a bar hanger having a C-shaped profile by superposing the bar hanger member on the identical bar hanger member in an inverted configuration, with the second protrusion of the bar hanger engaging in the channel of the identical member through the first slot of the identical member, and the first protrusion of the identical member engaging in the channel of the bar hanger member through the second slot of the bar hanger member.
According to an aspect, a bar hanger member is provided. The bar hanger member is for assembling with another like-member by superposition thereon to form a bar hanger for supporting recessed luminaires. The bar hanger member includes: an elongated body extending along a lengthwise axis between first and second ends, the elongated body having a front face and a rear face; a channel extending through the body along the lengthwise axis, and opening on the front and rear faces; and first and second protrusions extending from the body aligned with the channel along the lengthwise axis, the first and second protrusions being sized and shaped for slidable engagement with the channel of the like-member, the first protrusion extending from the front face of the body and the second protrusion extending from the rear face of the body, and when the bar hanger is assembled with the like-member, the second protrusion of the bar hanger engaging in the channel of the like-member and the first protrusion of the like-member engaging in the channel of the bar hanger member.
According to an aspect, a bar hanger member is provided. The bar hanger is for assembling with another like-member to form a bar hanger for supporting recessed luminaires. The bar hanger member includes: an elongated body extending along a lengthwise axis between first and second ends, the elongated body having a front face and a rear face; a channel extending through the body along the lengthwise axis and opening on the front and rear faces, the channel having a consistent width; and at least one protrusion extending from the body and aligned with the channel along the lengthwise axis, the at least one protrusion including a substantially planar stem having a width greater than the width of the channel, the stem being angled relative to the channel for sliding along the channel of the like-member when engaged therewith. The bar hanger member is assembled with the like-member by engagement of the at least one protrusion in the channel of the like-member, the stem of the at least one protrusion being twistable to lock the at least one protrusion in a fixed position along the channel of the like-member.
According to an aspect, a bar hanger member is provided. The bar hanger member is for assembling with another like-member to form a bar hanger for supporting recessed luminaires. The bar hanger member includes: an elongated body extending along a lengthwise axis, the elongated body having a substantially L-shaped profile; and an attachment mechanism on the elongated body for engaging the bar hanger member with the like-member when the like-member is inverted and the bar hanger member is superposed thereon. When assembled, the bar hanger member and the like-member together form the bar hanger having a substantially C-shaped profile.
According to an aspect, a bar hanger member is provided. The bar hanger member is for assembling with another identical bar hanger member to form a bar hanger for supporting recessed luminaires. The bar hanger member has a unitary body including: an elongated section extending along a lengthwise axis, the elongated section having a substantially L-shaped profile; an attachment mechanism on the elongated section for engaging the bar hanger member with the identical bar hanger member when the bar hanger member and the identical member are inverted relative to one another; and an attachment bracket extending from an end of the elongated section for securing the bar hanger member to a joist.
According to an aspect, a bar hanger member is provided. The bar hanger member is for assembling with another like-member to form a bar hanger for supporting recessed luminaires. The bar hanger member has a unitary body including: an elongated section extending along a lengthwise axis; an attachment mechanism on the elongated section for engaging the bar hanger member with the identical bar hanger member when the bar hanger member and the identical member are inverted relative to one another; and an attachment bracket extending from an end of the elongated section for securing the bar hanger member to a joist, the attachment bracket including a mounting plate, two positioning tabs extending from opposite ends of the mounting plate, and slots extending between the mounting plate and each positioning tab to allow the positioning tabs to be deflected relative to the mounting plate.
According to an aspect, a bar hanger member is provided. The bar hanger member is for assembling with another like-member to form a bar hanger for supporting recessed luminaires. The bar hanger member has a unitary body including: an elongated section extending along a lengthwise axis; an attachment mechanism on the elongated section for engaging the bar hanger member with the like-member when the bar hanger member and like-member are inverted relative to one another, and an attachment bracket extending from an end of the elongated section for securing the bar hanger member to a joist, the attachment bracket including a mounting plate, and two positioning tabs extending from opposite ends of the mounting plate, the positioning tabs each comprising a slot open at one end for sliding along and being removed from a supporting nail.
According to an aspect, a bar hanger member is provided. The bar hanger member is for assembling with another like-member to form a bar hanger for supporting recessed luminaires. The bar hanger member has a unitary body including: an elongated section extending along a lengthwise axis; an attachment mechanism on the elongated section for engaging the bar hanger member with the like-member when the bar hanger member and the like-member are inverted relative to one another; an attachment bracket extending from an end of the elongated section for securing the bar hanger member to a joist; and an angled notch at the end of the elongated section adjacent the attachment bracket for resting on a T-bar, the angled notch urging the bar hanger towards a top of the T-bar when the bar hanger is secured thereto.
In the following description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features of the present invention and references to some components and features may be found in only one figure, and components and features of the present invention illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are preferred, for exemplification purposes only.
It is to be understood that certain descriptions of embodiments have been simplified to illustrate only those elements and limitations that are relevant to a clear understanding, while eliminating, for purposes of clarity, other elements. Those of ordinary skill in the art, upon considering the present description, will recognize that other elements and/or limitations may be desirable. However, because such other elements and/or limitations may be readily ascertained by one of ordinary skill upon considering the present description, and are not necessary for a complete understanding, a discussion of such elements and limitations is not provided herein. As such, it is to be understood that the description set forth herein is merely exemplary and is not intended to limit the scope of protection.
With reference to
The elongated section 15 has a length 5, extending along a lengthwise axis 6 between a first end 7 and a second end 9. In the present embodiment, the elongated section 15 is substantially flat and planar, and comprises a front face 11 and a rear face 13, and an aperture opening on the front and rear faces 11, 13. The aperture comprise a channel 19 extending centrally in the elongated section 15 along the lengthwise axis 6, substantially along the entire length 5 of the elongated section. In the present embodiment, the channel 19 is a narrow cut-out in the body 3 having a nominal width 49. Preferably, the channel is continuous, uniform and smooth along its length, allowing a member engaged therein to slide there along uninterrupted. It is appreciated that in other embodiments, other configurations of the channel 19 are also possible. For example the channel 19 can be a groove formed in the body 3, and can open on only one of the front 11 and rear 13 faces. In other embodiments, two or more channels can be provided, and the channels may be offset from the center of the elongated section 15. The channels can further span a partial length of the elongated section, can be non-uniform, and/or can be provided with textured contours (such as bumps or teeth), for example to provide friction or resistance to sliding along segments of the channels.
With further reference to
The head section 17 extends from the elongated section 15 at the second end 9 thereof. In the present embodiment, the head section 17 extends entirely on the front side of the bar hanger member 1, i.e. in the facing direction of the front face 13, and preferably on a side of the bar hanger member 1 opposite the horizontal section 34 of the elongated section 15. Preferably, the head section 17 is formed by bending a portion of the body 3 frontwards. It is appreciated, however, that other configurations of the head section 17 are also possible. For example, the head section 17 can extend fully or partially on the rear side of the bar hanger member 1, and/or can extend from the first end 7 of the elongated section 15.
In the present embodiment, the elongated section 15 and the head section 17 are joined via a bridge 18. The bridge 18 is a narrow section of the body 3 which connects at one end to the elongated section 15 and at the other end to the head section 17. With further reference to
The head section 17 is preferably configured to secure the bar hanger member 1 to a support member in a ceiling, and can therefore also be referred to as an attachment bracket. In the present embodiment, the head section 17 comprises a mounting plate 35 extending at a substantially right angle relative to the elongated section 15. The mounting plate 35 is susbantially planar, such that it can be positioned flat up against a side of a support member, such as a ceiling joist. The mounting plate 35 comprises apertures 43 for receiving fastening means, such as screws or nails. In the resent embodiment, the mounting plate 35 further comprises an integrated nail 45. Preferably, the integrated nail 45 is provided in a retracted position, and can be hammered into a wooden joist for securing the bar hanger member 1 thereto without the need to external fasteners, or in combination with other fasteners to provide additional retention. It is appreciated that other configurations of the mounting plate 35 are also possible. For example, the mounting plate 35 can be provided with a different number, arrangement and size of apertures, and can be configured to secure the bar hanger member 1 with different fastening means.
The head section 17 is further provided with positioning tabs 37 for aligning the head section 17 with a ceiling joist. In the present embodiment, the positioning tabs 37 comprise an abutment member 47 extending away from the mounting plate 35. The positioning tabs 37 are configured such that when the head section 17 is positioned on a ceiling joist, the abutment member 47 abuts against an upper or lower edge of the ceiling joist, thus maintaining the head section 17 in vertical alignment with that edge. The abutment member 47 further comprises apertures 41 for securing the alignment tabs 37 to the ceiling joist via fasteners. In the present embodiment, two apertures 41a and 41b are provided. Aperture 41b is a slot which opens on one edge of the abutment member. As can be appreciated, in this configuration, the positioning tab 37 can slide along a fastener partially inserted through the slot 41b. The positioning tab 37 can further be disengaged from the fastener by sliding it past the open end of the slot 41b. It is appreciated that in other embodiments, a different combination of apertures 41 and configurations are possible, and that the positioning tabs 37 can be configured to be secured to ceiling joist via different attachment means.
In the present embodiment, the positioning tabs 37 are spaced apart from the mounting plate 35 via a deflecting slot 39. The deflecting slot 39 is a cut-out extending width-wise in the head section 17 and having an open end and a closed end. The open end opens on an edge of the head section 17, while the closed end defines a narrow strip of material connecting the mounting plate 35 and the positioning tabs 37. In the present embodiment, the entire body 3, including the narrow strip of material, is formed from sheet metal. As such, the positioning tabs 37 can be deflected relative to the mounting plate 35 by bending along the narrow strip of material defined by the deflecting slot 39. It is appreciated that in other embodiments, the positioning tabs 37 can be deflected relative to the mounting plate 35 using different structural configurations, such as by allowing complete removal of the positioning tabs 37, for example using score lines and/or by using a more brittle material to connect the mounting plate 35 and positioning tabs 37.
As can be appreciated, in the present embodiment, the head section 17 is configured such that it can engage with a support member both when upright and when in an inverted configuration. More specifically, the head section 17 is configured to be substantially symmetric about the lengthwise axis 6, including symmetric top and bottom positioning tabs 37a and 37b, and apertures 43 arranged in a symmetric configuration. The integrated nail 45 is configured to be hammered in through the center of a substantially symmetric opening in the mounting plate 35, thus allowing it to be secured to a joist in any orientation.
The illustrated bar hanger member 1 is configured to engage with another like-member, and preferably with an identical bar hanger member, in order to form a bar hanger for supporting a recessed luminaire. With reference to
To facilitate assembly, the bar hanger member 1 is provided with engagement mechanisms allowing it to engage with, and secured to, the identical bar hanger member 1′. The engagement mechanisms can also be referred to as interlocking mechanisms. A first engagement mechanism allows two bar hanger members 1, 1′ to be assembled with an adjustable or telescopic length. With reference to
In the present embodiment, two protrusions 21a, 21b are formed in the body 3 of the bar hanger member 1. The first protrusion 21a extends from the front face 11 of the elongated section 15, whereas the second protrusion 21b extends from the rear face 13 of the elongated section. The first 21a and the second 21b protrusions are spaced apart from one another and are positioned proximate the first end 7 of the elongated section 15. They are further positioned in alignment with the channel 19 along the lengthwise axis 6. Similarly, first and second channel slots 23a, 23b are formed along the channel 19. Both slots 23a, 23b are positioned proximate the first end 7 of the elongated section 15, and are spaced apart from one another, preferably by the same distance separating the protrusions 21a, 21b.
As best illustrated in
Preferably, the stem 51 and head 53 are dimensioned to allow the protrusions 21 to engage in, and to slide along, the channel 19 of an identical bar hanger member. In the present embodiment, the protrusions 21 are oriented relative to the channel 19 at an angle ϕ, such as between approximately 30° and 60°, and preferably approximately 45°. In this configuration, the width 55 of the stem 51 has a vertical component 59 which is smaller than the width 55. Similarly, the width 57 of the head 53 has a vertical component 61 which is smaller than the width 57. The stem 51 is dimensioned such that the vertical component 59 is smaller than or equal to the nominal width 49 of the channel 19 of the identical bar hanger member, allowing the stem 51 to fit there-through and to slide there-along. Similarly, the head 53 is dimensioned such that the vertical component 61 is larger than the nominal width 49 of the channel 19 of the identical bar hanger member, such that the head 53 cannot fit through the channel 19.
In the present embodiment, the channel slots 23 are also oriented relative to the channel 19 at an angle θ, which preferably corresponds to the angle ϕ of the protrusions, i.e. approximately 45°. The channel slots 23 have a width 63 which is preferably greater than the width 57 of the protrusion head 53. In this configuration, the protrusions 21 and channel slots 23 are complementary in shape and size, such that when the protrusion 21 is aligned with the slot 23, the head 53 can fit therethrough and initiate an engagement in the channel 19.
Preferably, the width 55 of stem 51 is greater than the nominal width 49 of channel 19. In this configuration, while oriented at angle ϕ, the protrusion 21 can slide freely along channel 19. However, the protrusion 21 is preferably made of a malleable material, such as sheet metal, which can preferably be twisted or rotated such that the protrusion 21 is oriented substantially vertically. In this configuration, when twisted, the vertical component 59 of the stem 51 increases up to the width 55 while the stem is inside the channel 19 of the identical bar hanger member. Since the width 55 is greater than the width 59, the stem 51 will lock in the channel 19, and will no longer be able to slide there along. As such, the protrusions 21 can also be referred to as locking tabs. As can be appreciated, the protrusions 21 need not be twisted so that they are fully vertical, and can, for example, be twisted only ⅛ of a turn to engage. Further, in configurations where the stem 51 is tapered, the channel 19 of the identical bar hanger member will be drawn towards the base of the stem 51 (i.e. where the stem is narrowest) when the stem 51 is twisted, thus drawing the bar hanger member 1 closer to the identical bar hanger member when the locking tab 21 is operated.
As best illustrated in
Preferably, the members 1, 1′ are sized so that when engaged as described above, the bar hanger 100 can be adjusted to span a distance between at least 16″ and 24″. In the present embodiment, the members 1, 1′ are configured to be adjusted between at least three predefined positions to span 24″ spaced T-bars, 24″ spaced joists, and 16″ spaced joists. However, it is appreciated that the member 1, 1′ can be adjusted to fit any distance therebetween. Alignment of members 1, 1′ at the predefined positions can be facilitated via markings 67 provided on the front and/or rear faces 11, 13 of the members 1, 1′. For example, an alignment market 67a can facilitate the alignment of the ends of both members 1, 1′ to initiate engagement, and length markers 67b, 67c, 67d can aid in aligning the members 1, 1′ to achieve a desired spanning distance. As can be appreciated, the markings can be used to align and lock members 1, 1′ to the proper size before ceiling installation.
In the present embodiment, the bar hanger 100 can be extended to span distances greater than 24″. As illustrated in
In order to extend the bar hanger 100, a second engagement mechanism is provided for securing two members 1, 1′ in an end-to-end configuration. With reference to
As best illustrated in
In the present embodiment, the bar hanger 100 is further configured to span distances smaller than 16″. More specifically, with reference to
As can be appreciated, when member 1 is cut, it can be assembled with another identical cut member 1′ in order to form a bar hanger 100 which spans a reduced distance. In the present embodiment, cutting along the cut area 27 removes the apertures 21. Therefore, a third engagement mechanism is provided to secure bar hanger members 1 of reduced length. More particularly, as shown in
In the present embodiment, the bendable member 29 is a partial cut-out in the body 3 which can be manually bent in the direction of the front face 11 or in the direction of the rear face 13. Preferably, the bendable member 29 is narrow, elongated and tapered, and thus resembles an arrowhead. The slot 31 is preferably uniform in size, and configured to receive a portion of the bendable member 29 therein in a locking configuration. It is appreciated, however, that other configurations are also possible.
As best illustrated in
With reference now to
A shortened bar hanger 100′ is shown in the installed configuration in
As can be appreciated, the above-described embodiments have a number of advantages. For example, a bar hanger can be assembled using identical members, making it easier to assemble, and less costly to manufacture. A bar hanger can further be assembled without requiring external fasteners, and using simple tools, such as standard pliers. Moreover, the engagement mechanisms are configured such that components are drawn together when engaged, reducing unwanted play and improving rigidity. Finally, several features have been provided which generally facilitate the installation of the bar hanger compared to existing systems. The bar hanger members can be provided individually and/or as part of a kit which may include several bar hanger members, and/or butterfly brackets and/or sliding brackets for installation. The kit can further include instructions for assembling the bar hanger members.
While the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto.
Claims
1. A bar hanger member for assembling with a like-member to form a bar hanger for supporting recessed luminaires, the bar hanger member comprising:
- an elongated body extending along a lengthwise axis between first and second ends, said elongated body having first and second faces;
- at least one channel extending through the body along the lengthwise axis, and opening on at least on one of the first or second faces;
- a first protrusion extending from the first face and positioned to engage in and slide along the at least one channel in the like-member when the bar hanger member is superposed on the like-member; and
- a second protrusion extending from the second face and positioned to engage with the like-member when the like-member is superposed on the bar hanger member.
2. The bar hanger member according to claim 1, wherein the second protrusion is positioned to engage in and slide along the at least one channel in the like-member when the like-member is superposed on the bar hanger member.
3. The bar hanger member according to claim 1, wherein the channel comprises a width, further wherein the first protrusion comprises a width greater than the width of the channel.
4. The bar hanger member according to claim 3, wherein a width-wise axis of the first protrusion is angled between 30° and 60° relative to a width-wise axis of the channel.
5. The bar hanger member according to claim 1, wherein the at least protrusion comprises a stem extending from the first face of the body, and a head extending from the stem.
6. The bar hanger member according to claim 5, wherein the stem has a vertical component smaller than a width of the channel, and the head has a vertical component greater than the width of the channel.
7. The bar hanger member according to claim 6, wherein the vertical component of the stem is tapered inward from the head to the first face of the body.
8. The bar hanger member according to claim 1, wherein the elongated body comprises an L-shaped profile, further wherein the bar hanger formed by superposing the bar hanger member on the like-member comprises a C-shaped profile.
9. The bar hanger member according to claim 8, wherein the elongated body comprises a planar vertical section comprising the first and second faces, and a planar horizontal section extending from the planar vertical section at a right angle.
10. A bar hanger member for assembling with a like-member to form a bar hanger for supporting recessed luminaires, the bar hanger member comprising:
- an elongated body extending along a lengthwise axis between first and second end, said elongated body having a first face and a second face;
- a first protrusion extending from the first face, the first protrusion being configured to engage with the like-member when the bar hanger member is superposed on the like-member; and
- a second protrusion extending from the second face, the second protrusion being configured to engage with the like-member when the like-member is superposed on the bar hanger member.
11. The bar hanger member according to claim 10, wherein the first and second protrusions are configured for slidable engagement with the like-member.
12. The bar hanger member according to claim 10, further comprising at least one aperture opening on the first and second faces, wherein the first protrusion is sized and positioned to engage in the at least one aperture in the like-member when the bar hanger member is superposed on the like-member, and wherein the second protrusion is sized and positioned to engage in the at least one aperture in the like-member when the like-member is superposed on the bar hanger member.
13. The bar hanger member according to claim 12, wherein the aperture comprises a channel extending through the body along the lengthwise axis, further wherein the first and second protrusions are configured to slide along the channel when engaged in the aperture of the like-member.
14. The bar hanger member according to claim 10, further comprising at least one interlocking mechanism operable to lock the bar hanger member and the like-member together.
15. The bar hanger member according to claim 14, wherein the interlocking mechanism comprises at least one locking tab positioned to engage in a corresponding aperture in the like-member.
16. The bar hanger member according to claim 15, wherein the first and second protrusions comprise the at least one locking tab.
17. The bar hanger member according to claim 15, wherein the at least one locking tab is twistable to lock in the aperture.
18. The bar hanger member according to claim 17, wherein the at least one locking tab comprises a tapered stem configured to draw the bar hanger member and the like-member together when the at least one locking tab is twisted.
19. A kit for forming a bar hanger, the kit comprising at least two bar hanger members comprising:
- a first bar hanger member comprising: an elongated body extending along a lengthwise axis between first and second ends, said elongated body having a front face and a rear face; an aperture opening on the front face; and a protrusion extending from the front face; and
- a second bar hanger member comprising: an elongated body extending along a lengthwise axis between first and second ends, said elongated body having a front face and a rear face; an aperture opening on the rear face; and a protrusion extending from the rear face;
- wherein the protrusion of the first bar hanger member is positioned to engage in the aperture of the second bar hanger member and the protrusion of the second bar hanger member is positioned to engage in the aperture of the first bar hanger member when the second bar hanger member is superposed on the first bar hanger member.
20. The kit according to claim 19, wherein the first and second bar hanger members are identical members.
Type: Application
Filed: May 25, 2018
Publication Date: Oct 18, 2018
Inventors: Abdelkrim Oudina (Montreal), Lloyd Sevack (Dollard-des-Ormeaux), John Payne (Repentigny), Jenna Sevack (Dollard-des-Ormeaux)
Application Number: 15/989,908