Ceiling Fan Mounting Apparatus

1. Field of the Invention

The invention relates generally to mounting apparatus useful for supporting a fan or similar device from the ceiling of a building structure. In particular, the invention provides methods and apparatus for mounting a fan or similar device from the ceiling of various types of building structures, including the ceilings of different levels in multi-level buildings and from the ceilings of mobile homes or the like.

2. Description of the Prior Art

Ceiling fans and similar devices are often mounted within a living space in a building, mobile home or the like at a time subsequent to completion of the building. Such retrofit situations usually find installation being performed by relatively unskilled persons with the result that the installation is not as secure as is desirable and the installation is unsafe. Further, it is often very difficult for such relatively unskilled installers to easily mount a ceiling fan with the mounting structure previously available to them, damage to the building structure and to the device being installed often occurring due to the difficulty of mounting previous support structure.

In many prior situations, a ceiling fan or similar device is mounted with a hook having an upper end portion formed as a woodscrew for insertion into a ceiling rafter or joist. However, such a prior arrangement does not usually provide a flush mounting to the ceiling and is therefore not as attractive as is desired. Further, with fans which are reversible, such installations are dangerous in that the motion of the fan can actually unscrew the threaded hook, thereby causing damage to the fan and potential serious injury to occupants of a living space in which the fan is being used.

In mobile homes, a light weight ceiling construction is typically encountered, conventional ceilings in mobile homes being comprised of a plurality of truss assemblies which are often on 16" centers. The ceiling itself in a mobile home is generally comprised of a light weight plywood, pressed board or similar materials, thereby making the installation of a relatively heavy ceiling fan or other device an impossibility with such ceilings due to the inability of such ceilings to support the necessary weight.

Retrofit mountings of ceiling fans and similar devices within conventional buildings also differ depending upon whether the fan is to be mounted in a ceiling which has space above the ceiling joists. For example, in a multi-level house, the retrofit (and initial) mounting of a ceiling fan differs in the ceiling just below a non-floored attic as opposed to the ceiling between two living levels. A ceiling existing between two living levels typically has joists with flooring disposed against the top surfaces thereof with no space being thus available to mount structure over the top surfaces of the joists for supporting a fan or other device in the lower living level.

Ceiling mounting situations also exist where it is desirable to be able to place a supporting bar over or against ceiling joists and then attach hardware for mounting an outlet box. In these and other situations, it is also desirable to be able to adjust the position of the mounting hardware and thus the outlet box along virtually the full length of the supporting bar.

The present invention intends solutions to the several problems described above by providing easily installed and safe apparatus capable of being installed in its several embodiments in both mobile homes and in the various ceiling/flooring situations existing in multi-level buildings.

The invention provides methods and apparatus for efficiently and safely mounting a fan or simlar device to the ceiling of a dwelling or similar environmental space such as a conventional home, mobile home, or the like. In a first embodiments, the apparatus of the invention comprises an elongate bar-like member having at least one aperture formed medially of its length to receive threaded inserts for mounting a threaded rod or hook at right angles to the longitudinal axis of the member, an electrical outlet box and a fan being carried by the threaded rod or hook to mount same against a ceiling. The elongate member can preferably be tubular with its ends being downturned to allow convenient mounting of the elongate member over upper surfaces of ceiling joists so as to distribute the weight of the fan over a relatively large portion of the ceiling. In mobile homes, where ceiling joists are of small size and light weight, it is absolutely necessary to spread the weight of the fan over portions of the building structure greater than a single joist. The elongate member can be provided with a series of apertures such that the threaded rod or hook can be placed along portions of the member to facilitate adjustment of the member over the joist and the threaded rod or hook in alignment with a hole cut in the ceiling in a retrofit situation.

A further embodiment of the invention is particularly useful in the mounting of a fan or the like in a situation where space does not exist above a ceiling joist, that is, the ceiling joists are used as a support surface for flooring of a living level above that living level within which the fan is to operate. In this embodiments of the invention, an elongate member having telescoping end sections is inserted between two joists with longitudinally disposed woodscrews extending one each from each telescoping section to allow connection to each joist. The telescoping end sections are provided with plates of a diameter sufficient to mount the structure at a desired distance above a hole cut in a ceiling to facilitate mounting of the apparatus in a retrofit situation.

In another embodiment of the invention, a hook having a threaded shank is placed over a supporting bar which extends between two joists, the hook being movable along the bar to any position where a fan or the like is to be mounted. The threaded shank of the hook is provided with a double-nut element having two threaded lumens, one to receive the shank of the hook and the other to receive a threaded bolt which can be tensioned against the bar to hold the hook in place at a desired position along the bar. The outlet box is mounted to the shank of the hook.

It is therefore an object of the present invention to provide apparatus for mounting a fan or similar device to the ceiling of a building or mobile home to accommodate varying situations existing in such structures.

It is also an object of the invention to provide apparatus for mounting a fan or similar device to a ceiling of a mobile home and wherein the apparatus comprises an elongate tubular member capable of spanning upper surfaces of adjacent joists and to be supported thereover in a position to dispose a vertical rod or hook mounted to the member over an opening in the ceiling such that a fan can be hung from the vertically oriented rod or hook.

It is another object of the present invention to provide a method and apparatus for mounting a ceiling fan or similar device to a ceiling of a building wherein ceiling joists also serve as supports for flooring of a living space surmounting that living space within which the fan is to operate, the invention including a bar from which a vertically arranged threaded rod or hook is mounted in alignment with a hole in a ceiling and wherein the member has telescoping end portions which are fastened to the sides of the ceiling joists by means of woodscrews extending longitudinally from the end portions.

It is another object of the invention to provide low cost apparatus which allows adjustment of the position of a ceiling fan or similar device along essentially the full length of a support bar extending between ceiling joists and wherein the apparatus can be attached to the bar either before or after the bar is in place between the joists.

It is another object of the invention to provide apparatus wherein the vertical position of a junction box and thus a ceiling fan or similar device mounted thereinto can be adjusted relative to a support bar extending between ceiling joists.

It is a further object of the present invention to provide methods and apparatus for mounting a ceiling fan or similar device to ceiling joists regardless of the arrangement of the ceiling joists relative to ceiling or flooring structure associated therewith.

Further objects and advantages of the invention will become more readily apparent in light of the following detailed description of the preferred embodiments.

FIG. 1 is a perspective view of a portion of joists arranged in a ceiling and having space surmounting the joists such that apparatus according to the invention can be mounted thereover;

FIG. 2 is a detailed view partially cut away of apparatus according to the invention being mounted over a ceiling joist;

FIG. 3 is a side elevational view in partial section illustrating the mounting of a ceiling fan utilizing apparatus according to a first embodiment of the invention wherein an elongate bar is mounted over upper surfaces of adjacent ceiling joists;

FIG. 4 is a plan view illustrating an alternate embodiment of the invention wherein a plurality of apertures are formed in an elongated bar mounted over adjacent ceiling joists, the apertures allowing adjustment of the apparatus to dispose at least one of the apertures over a hole located in a ceiling and through which hole connection to a fan or the like is accomplished;

FIG. 5 is a side elevational view illustrating the embodiment of FIG. 4 in an operative environment;

FIG. 6 is a side elevational view in partial section illustrating an apparatus according to a first embodiment of the invention and wherein a two-pronged mounting bracket is utilized to mount a ceiling fan to a ceiling;

FIG. 7 is a perspective view illustrating a further embodiment of the invention which allows the apparatus of the invention to be mounted between ceiling joists;

FIG. 8 is a detailed view illustrating connection of a telescoping end portion of the apparatus of FIG. 7 to one of the adjacent joists to which the apparatus is fastened;

FIG. 9 is a side elevational view illustrating the completed mounting of the apparatus of FIG. 7 with an electrical outlet box and the fan mounted therefrom;

FIG. 10 is a side elevational view in partial section of a further embodiment of the invention illustrating a mounting arrangement which is adjustable along the length of a support bar, the mounting arrangement being shown in the unlocked configuration;

FIG. 11 is a side elevational view in partial section of the mounting arrangement of FIG. 10 in the locked configuration; and,

FIG. 12 is a plan view of the double nut element of FIGS. 10 and 11.

Referring now to the drawings and particularly to FIGS. 1 through 3, a mounting apparatus shown generally at 10 in FIG. 3 according to a first embodiment of the invention is seen to comprise an elongate tubular member 12 which is disposed in surmounting relation to and in contact with upper surfaces of adjacent joists 13 forming a portion of a ceiling such as in a mobile home or conventional building. As is particularly shown in FIG. 1, a hole 14 is cut in ceiling 15 to allow the tubular member 12 to be inserted through said ceiling 15 and into position over the joist 13. During this installation operation, the tubular member 12 may be positioned without associated structure which will subsequently be described in order to facilitate positioning of said tubular member 12 over the joist 13. Alternatively, the tubular member 12 may be inserted through the hole 14 and positioned properly relative to said hole 14 with other portions of the mounting apparatus 10 being attached thereto as will be described. Referring to FIG. 1, it is seen that the tubular member 12 is extended upwardly through the hole 14 with one end of said member 12 being positioned over one of the joists 13 and the tubular member 12 then being fully extended through the hole 14 with the last end through the hole being brought backwardly into a contacting relation with the other joists 13 such that the tubular member 12 rests over both of said joists 13. The tubular member 12 is thus in position to mount a ceiling fan or other device as will be hereinafter described.

As best seen in FIGS. 2 and 3, the tubular member 12 is formed with a channel-like aperture 16 which is preferably disposed equidistantly from the ends of the member 12 or along the axial center line as is shown in FIG. 2. The tubular member 12 can be reduced in diameter at 17 to form a flattened indentation which accommodates upper surfaces of an outlet box 22 in those situations where the height of the joists 13 and/or the thickness of the ceiling 15 provide insufficient vertical distance to allow the box 22 to be flush with the ceiling 15. In FIG. 3, the height of the joists 13 is sufficient such that the area 17 is not utilized. The aperture 16 receives a threaded insert 18 which is fixedly mounted within the aperture 16. The threaded insert can take the form of a simple nut or a T-nut which is welded within the aperture 16. Regardless of the exact form taken by the threaded insert 18, the function of the insert 18 is to receive one end of a threaded rod 19, the rod 19 extending downwardly from the tubular member 12 to extend through the hole 14 formed in the ceiling 15. In the embodiment shown in FIG. 3, the threaded rod 19 has a hook 20 disposed at its lowermost end, the hook 20 mounting the ceiling fan. A rod having a single hook 20 at the lower end thereof is not suitable for fans which can be reversed in rotational direction. Such fans are to be mounted with the structure shown in FIG. 5 as will be described hereinafter.

The threaded rod 19 also mounts the electrical outlet box 22 between the tubular member 12 and the hook 20. The outlet box 22 is of a size which fits flushly within the hole 14 and, in fact, the hole 14 is cut to a size such that the outlet box 22 will fit flushly therewithin. The box 22 can be provided with a lip 23 which abuts the periphery of the hole 14 and aids in supporting the ceiling 15 due to the supporting action of the present apparatus. The outlet box 22 is held in place on the threaded rod 19 by means of cooperating nuts and washers 24 and 26 respectively, the nuts 24 being snugged down into contact with the outlet box 22 to allow placement of said box 22 at a desired location on the rod 19. Similarly, a nut 28 and washer 30 is snugged up against lower surfaces of the tubular member 12 in order to "lock" the threaded rod 19 in a desired position relative to the tubular member 12. Of course, the upper end of the threaded rod 19 is received within the threaded insert 18 at a desired insertion to cause the hook 20 to extend a desired distance from the ceiling 15.

The tubular member 12 can also be formed with downturned ends 32 which prevent slippage of the mounting apparatus 10 from the joist 13. The ends 32 can simply comprise crimping of the ends of the tubular member 12 with an arcuate bending of the crimped ends to provide the desired function.

Referring now to FIGS. 4 and 5, a mounting apparatus configured according to another embodiment of the invention is seen to comprise a tubular member 34 which is substantially identical to the tubular member 12 of FIGS. 1 through 3. However, the tubular member 34 is formed with a series of three apertures 36 extending along one half portion thereof, the apertures 36 receiving threaded inserts 38 of the type which comprise the threaded insert 18. In use, the tubular member 34 need not be positioned precisely in order to align with a hole (not shown) in a ceiling, shown in phantom at 40, any one of the apertures 36 being positionable above said hold depending upon the location at which the hole is cut in the ceiling 40. In other words, a hole which is cut between joists 42 in FIGS. 4 and 5 can be effectively located any where between said joists 42 and the plurality of apertures 36 and threaded inserts 38 received therein allows alignment of one of the apertures 36 with said hole in order that threaded rod 44 can be properly aligned with said hole. The threaded rod 44 essentially corresponds to the threaded rod 19 of FIG. 3. However, the threaded rod 44 is not provided with a hook at the end thereof but simply comprises a rod which is threaded along its entire length in order to mount a double prong mounting bracket 46 at the lowermost end thereof. As can readily be seen, the bracket 46 is mounted to an outlet box 48 carried on the threaded rod 44, the bracket further being attached to the rod 44 by means of nuts 50 and 52 respectively. Two, three or more of the apertures 36 can be used and the innermost aperture 36 can be at the center of the tubular member 34 as is the aperture 16 in FIG. 3. Spacer washers 41 can be employed to snug the member 34 to the top of the outlet box 48 in those situations where the height of the joists 42 allow such modification. Otherwise, as in the situation shown in FIG. 5, the washers 41 are not necessary.

As seen in FIG. 6, an outlet box such as outlet box 48 and a double pronged mounting bracket 46 can be mounted by a threaded rod 54 and associated nuts and washers on a tubular member 56 having only a single aperture centrally disposed on the tubular member as is shown in FIG. 6. It is to be understood, however, that hole 58 cut in ceiling 60 must be generally positioned in order that the threaded rod 54 can be made to properly align with the hole 58. The fact that the tubular member 56 is generally longer than the spacing between joist 62 allows a certain degree of adjustment to be made by lateral movement of the tubular member 56 relative to the joists 62. As is also seen in FIG. 6, a fan 64 can be readily mounted to the bracket 46 in a conventional manner, the bracket 46 allowing mounting of a fan which has a reverse directional capability.

As is also seen in FIG. 6, barbed pads 66 can be attached at each end of the tubular member 56 at opposite ends of said member for engagement in the joist 62 to fix the mounting apparatus to the joist 62. The pad 66 can be relatively wide in order to allow the lateral adjustment of the tubular member 56 as discussed above. Barbs 68 can be struck from the pads such as by stamping in order to provide sharp points capable of cutting into the joist 62. A lip 49 can be provided about at least portions of the periphery of the opening of the outlet box 48, the lip 49 functioning in the manner of the lip 23 seen in FIG. 3 to support that portion of the ceiling 60 about the hole 58.

Referring now to FIGS. 7, 8 and 9, a further embodiment of the invention can be seen to be of particular use in a situation where the mounting apparatus must be used between the ceiling and a surmounting floor in a conventional home. In such situations, upper surfaces of joists 70 have flooring (not shown) disposed directly over the joists 70 and in contact with upper surfaces thereof. In such a situation, the mounting apparatus must be installed between two joists 70 and fastened thereto. As particularly seen in FIG. 7, mounting apparatus 72 is formed of a central sleeve 74 having an aperture 76 located medially of its length and receiving a threaded insert 78 thereinto. Of course, a series of apertures 76 and threaded inserts 78 could be formed in the sleeve 74 as is described above relative to certain other embodiments of the invention. The sleeve 74 is further provided with oppositely aligned slots 80 in each end thereof, the slots 80 being disposed diametrically across the ends of the sleeve 74 from each other. The sleeve 74 is also of a diameter which allows cylindrical end members to be telescopingly received within each end of the sleeve 74, the end members 82 being of a diameter which allows sliding receipt of said end members within the interior of the sleeve 74. The end members are of a length which do not extend completely to the aperture 76 formed in the sleeve 74. When one of the cylindrical end members 82 is fully received into an end of the sleeve 74, an end plate 84 connected to the outer end of the end member abuts against the end of the sleeve 74. Further, diametrically disposed pins 86 are further received into the slots 80 when the end member 82 is fully received into the sleeve 74. The fitting of the pins 86 into the slots 80 cause the end members 82 to rotate with the sleeve 74 when said sleeve 74 is rotated about its longitudinal axis. On the face of each end plate 84 opposite that face which connects to the end member 82 is disposed a woodscrew 88 which is centrally mounted to said end plate 84 and which extends outwardly thereof in alignment with the aligned longitudinal axes of the sleeve 74 and the cylindrical end members 82. The woodscrews 88 at each end of the mounting apparatus 72 can be fastened into the joists 70 in a manner to be described hereinafter.

Referring to FIG. 8, it is to be seen that a radius of each end plate 84 is equal to that distance between the longitudinal axis of the sleeve 74 and the upper surface of ceiling 90, this distance allowing outlet box 92 to be properly located within hole 94 in the ceiling 90 to facilitate mounting of a fan thereto. The end plates 84 are also preferably chosen as being circular in conformation in order to allow the mounting apparatus to be rolled along the upper surface of the ceiling 90 to properly position the mounting apparatus 72 between the joists 70.

As can be seen in FIG. 9, the sleeve 74 is further seen to have a hole 96 formed therein, the hole 96 not being shown in FIG. 7 for purposes of convenient illustration. The hole 96 is used to turn the sleeve 74 during installation of the mounting apparatus 72. In fact, a plurality of the holes 96 can be formed about the aperture 76 to facilitate turning of the sleeve 74 by means of a tool as will be described hereinafter. A lip 93 can be provided about at least portions of the periphery of the opening of the outlet box 92, the lip 93 functioning in the manner of the lips 23 and 49 of FIGS. 3 and 6 respectively as described above.

The installation of the apparatus of FIGS. 7, 8 and 9 is described in detail in U.S. Ser. No. 548,147, filed Nov. 2, 1983, now U.S. Pat. No. 4,538,786, and which is related to the present application, the disclosure of which is incorporated hereinto by reference.

The apparatus of FIG. 9 provides a feature which is of substantial importance. In particular, screws 104 aid in mounting the bracket 100 to the outlet box 92, this structure being conventional. The threaded rod 98, however, also mounts to the bracket 100 by virtue of nut 106 and nut 108 and washer 110 in a manner similar to that shown in other embodiments. This additional mounting provides a "fail-safe" or redundant mounting feature which causes the present mounting apparatus to exhibit additional safety capability relative to prior art mounting structures.

Considering again the sleeve 74 of FIGS. 7, 8 and 9, it is to be understood that the length of the sleeve 74 can be varied to accommodate different distances between the joists 70. In a commercial embodiment of the apparatus of FIG. 7, two sleeves 74 of different lengths are included so that the apparatus can be installed between joists having different distances between centers, one of the two different sleeve lengths being of an adequate length to accommodate differing "standard" distances between joists in conventional building situations.

Referring now to FIGS. 10 and 11, a support bar 119 is shown in actual section and is understood to comprise an elongated tubular member such as the tubular members 12 and 56 referred to hereinabove. The support bar 119 extends between two adjacent joists (not shown) in the manner of the tubular members 12 and 56 referred to above. The support bar 119 can be provided with arcuate end portions (not shown) such as the ends 32 shown in FIG. 3 inter alia. In the alternative, the support bar 119 can comprise a support element which extends between adjacent joists and is fixed thereto such as through the use of structure noted above in FIGS. 6 and 9 inter alia. In essence, the support bar 119 is a tubular element which, in this embodiment of the invention, does not need to be provided with holes for receiving mounting structure or the like. The support bar 119 is thus a continuous tubular element which may be fluted at its ends as aforesaid.

An adjustable mounting arrangement usable with the support bar 119 is shown generally at 120 and allows adjustment of the position of a ceiling fan (not shown) along substantially the entire full length of the support bar 119. The adjustable mounting arrangement 120 further provides the advantage that the arrangement 120 can be positioned on the support bar 119 either before or after the support bar 119 is placed on and/or between adjacent joists in a ceiling. The adjustable mounting arrangement 120 is then tightened at a desired location along the support bar 119 to allow subsequent mounting of a ceiling fan (not shown) or similar device to the support bar 119. The simplicity of the present mounting structure as embodied in the support bar 119 and the adjustable mounting arrangement 120 also allows production of an extremely low cost adjustable mounting device which is flexible in use to allow rapid readjustment of fan position as well as reuse.

The adjustable mounting arrangement 120 comprises a hook 122 having a threaded shank 124, the hook 122 fitting over the support bar 119 such that the threaded shank 124 extends downwardly from the support bar 119. In the unlocked position as shown in FIG. 10, a double nut element 126 is positioned on the threaded shank 124 such that sufficient clearance is available for the support bar 119 to be received into the bight portion of the hook 122. The double nut element 126 is provided with two threaded holes 128 and 130 which are spaced from each other, this structure also being seen in FIG. 12. The threaded hole 128 of the element 126 receives the threaded shank 124 while the threaded hole 130 receives a threaded bolt 132. The threaded holes 128 and 130 can be of different sizes in order to accommodate the respective diameters of the threaded shank 124 and the threaded bolt 132. Of course, the diameters of the holes 128 and 130 can be identical in the event that the diameters of the threaded shank 124 and the threaded bolt 132 are chosen to be the same. The double nut element 126 can be formed of flat stock with its periphery being rounded as shown in FIG. 12. As a practical matter, the peripheral shape of the element 126 can be chosen for manufacturing convenience.

As can be seen in FIG. 11, the element 126 is rotated about the threaded shank 124 to position the threaded bolt 132 immediately below the open portion of the hook 122 preparatory to locking of the mounting arrangement 120 to the support bar 119. The lower end of the threaded bolt 132 is provided with a head 134 having a standard slot formed therein for receipt of a screwdriver (not shown) or other tool for rotation of the bolt 32 and thus tightening of the bolt against the support bar 119 as shown in FIG. 11. Once the hook 122 is positioned along the support bar 119 in a desired position, the threaded bolt 132 is positioned as is shown in FIG. 11 immediately beneath the open portion of the hook 122 and tightened against the support bar 119 through the use of a tool such as a screwdriver. Free end of the bolt 132 thus contacts the support bar 119 and positively locks the mounting arrangement 120 to the support bar 119. As can be readily seen, the threaded bolt 132 can be backed off to allow release of the mounting arrangement 120 and thus readjustment as desired.

An electrical outlet box 142 can be mounted to the lower distal end of the threaded shank 124 by means of threaded nuts 138 and washers 140 as seen in FIGS. 10 and 11. The outlet box 142 can be mounted to the threaded shank 124 by the mounting arrangements shown in FIGS. 3, 5, 6 and 9 inter alia to provide the ability to vertically adjust the position of the outlet box 142 and thus a ceiling fan (not shown) or similar device relative to the support bar 119 and thus relative to a ceiling (not shown). The outlet box 142 can be provided with an inturned flange 144 as is common in the art and can also be provided with a lip 146 formed by at least portions of the periphery of the opening of the outlet box 142, the lip functioning in the manner of the lips 23, 49 and 93 of FIGS. 3, 6 and 9, respectively as described above.

The adjustable mounting arrangement 120 thus provides a simple yet reliable mechanism for adjustably positioning an electrical outlet box and a ceiling fan or similar device connected thereto along the length of the support bar 119. A ceiling fan or similar device can be connected to the outlet box 142 and/or to the end portion of the threaded shank 124 in any desirable manner such as that shown in FIGS. 3, 5, 6 and 9. The adjustable mounting arrangement 120 further provides the ability to lock the outlet box 142 into any desired position along the length of the support bar 119. The present structure provides advantages in the mounting of ceiling fans or similar devices during installation procedures since the mounting arrangement 120 can be connected to the support bar 119 either before or after the support bar 119 is properly positioned between ceiling joists, thereby allowing a flexibility of installation which is desirable due to the differences in ceiling structures encountered during such installations.

As can be appreciated from a review of the foregoing disclosure, modifications to the structure can be made without departing from the scope of the invention. In particular, the threaded inserts described as elements 18, 38 and 78 can take a number of forms as long as the function of receiving the threaded end of a vertical rod is provided. Further, the members 12, 34 and 56 can take other forms other than that of a tubular cylinder without departing from the scope of the invention. In essence, the scope of the invention can be seen to encompass a number of modifications and is thus to be interpreted in light of the recitations of the appended claims.