U.S. patent application number 12/151890 was filed with the patent office on 2008-10-02 for electrical junction assemblies for coupling electrical fixtures to suspending ceiling grids.
Invention is credited to Walter Blue Clark, Brian S. Hendrickson.
Application Number | 20080237227 12/151890 |
Document ID | / |
Family ID | 34988560 |
Filed Date | 2008-10-02 |
United States Patent
Application |
20080237227 |
Kind Code |
A1 |
Hendrickson; Brian S. ; et
al. |
October 2, 2008 |
Electrical junction assemblies for coupling electrical fixtures to
suspending ceiling grids
Abstract
A T-bar clip assembly that securely couples to T-bar structures
that are used to construct suspended ceiling is disclosed. The
T-bar assembly is configured to support one or more electrical
fixtures and provide power feeds to the one or more electrical
fixtures. The T-bar clip assembly comprises support brackets that
secure to the T-bar structures and one or more housing structures
that attach to a portion of the support brackets to form one or
more corresponding junction box enclosures. The junction box
enclosures provide the power feeds to the one or more electrical
fixtures at locations that are substantially flush with support
flanges of the T-bar structure, an outer surface of the removable
ceiling tiles or both.
Inventors: |
Hendrickson; Brian S.;
(Menlo Park, CA) ; Clark; Walter Blue; (Palo Alto,
CA) |
Correspondence
Address: |
JAG PATENT SERVICES LLC;ATTN: James A. Gavney
Suite 21, 1901 Old Middlefield Way
Mountain View
CA
94043
US
|
Family ID: |
34988560 |
Appl. No.: |
12/151890 |
Filed: |
May 9, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11077690 |
Mar 10, 2005 |
7374057 |
|
|
12151890 |
|
|
|
|
60552464 |
Mar 11, 2004 |
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Current U.S.
Class: |
220/3.9 ; 24/563;
248/342 |
Current CPC
Class: |
Y10T 24/44923 20150115;
H02G 3/263 20130101; H02G 3/20 20130101; H02G 3/34 20130101; Y10S
248/906 20130101 |
Class at
Publication: |
220/3.9 ;
248/342; 24/563 |
International
Class: |
H02G 3/08 20060101
H02G003/08; B42F 13/00 20060101 B42F013/00; A44B 21/00 20060101
A44B021/00 |
Claims
1. A clip assembly comprising: a) support brackets for securing
around a T-bar structure of a suspended ceiling grid; and b) a
housing structure for coupling to at least one of the support
brackets and thereby forming a recessed junction box enclosure
located above the suspended ceiling grid for supporting electrical
connections and providing a power feeds wherein a bottom portion of
the recessed junction box enclosure formed is substantially flush
with support flanges of the T-bar structure.
2. The clip assembly of claim 1, wherein the housing structure
includes a receiving aperture for coupling to a conduit.
3. The clip assembly of claim 1, wherein the housing structure
includes power feed support flanges to support power feed
wires.
4. The clip assembly of claim 1, wherein the housing structure
includes mounting tabs for coupling to at least one of the support
brackets.
5. The clip assembly of claim 1, wherein the at least one of the
support brackets comprises a flange tab that forms a top portion of
the junction box enclosure.
6. The clip assembly of claim 5, wherein the flange tab includes a
receiving aperture for coupling to a conduit.
7. The clip assembly of claim 1, wherein at least one of the
bracket structures includes a canopy stud for securing to an
electrical fixture.
8. The clip assembly of claim 1, wherein the support brackets
include means for securing to a building support.
9. An electrical junction assembly comprising: a) a vertical
housing support that securely couples to a T-bar structure of a
suspended ceiling grid; and c) a housing structure configured to
attach to the vertical housing support and form a junction box
enclosure with a bottom portion that has a power feed outlet
substantially even with support flanges of the T-bar structure.
10. The electrical junction assembly of claim 9, wherein the
vertical housing support is formed from a first support bracket and
a second support bracket that secure around the T-bar structure of
the suspended ceiling grid.
11. The electrical junction assembly of claim 9, wherein the
housing structure includes a receiving aperture for coupling to
conduit.
12. The electrical junction assembly of claim 9, wherein the
housing structure includes power feed support flanges to support
power feed wires.
13. The electrical junction assembly of claim 9, wherein the
housing structure includes mounting tabs for coupling to the
vertical housing support.
14. The electrical junction assembly of claim 9, wherein the
vertical housing support comprises a flange tab that forms a top
portion of the junction box enclosure.
15. The electrical junction assembly of claim 14, wherein the
flange tab includes receiving aperture for coupling to conduit.
16. The electrical junction assembly of claim 9, wherein the
vertical housing support includes means for attaching and
supporting an electrical fixture.
17. The electrical junction assembly of claim 9, wherein the
vertical housing support includes means for securing a building
support.
18. A method of making a T-bar clip assembly for securing to a
T-bar structure comprising a vertical support structure and
horizontal support flanges, the method comprising; a) forming a
support structure configured to secure to a T-bar structure and
form a vertical housing support that is parallel with the vertical
support structure of the T-bar structure; and b) forming a housing
structure configured to securely couple to the vertical housing
support and form a junction box enclosure that provides one or more
power feeds below the vertical support structure and substantially
flush with the horizontal support flanges.
19. The method of claim 18, wherein forming the support structure
comprises forming a first support bracket and a second support
bracket that secure around a cross-section of the T-bar
structure.
20. The method of claim 18, wherein forming a housing structure
comprises cutting a receiving aperture for coupling to a
conduit.
21. The method of claim 18, wherein forming a support structure
comprises cutting a flange tab that can be adjusted to form a
portion of the junction box enclosure.
Description
RELATED APPLICATION
[0001] This application is a Continuation application of the
co-pending application Ser. No. 11/077,690, filed Mar. 10, 2005,
and titled "ELECTRICAL JUNCTION ASSEMBLIES FOR COUPLING ELECTRICAL
FIXTURES TO SUSPENDING CEILING GRIDS," which claims priority under
35 U.S.C. .sctn.119(e) from the Provisional Patent Application Ser.
No. 60/552,464, filed on Mar. 11, 2004, and titled "INTEGRATED TEE
BAR CLIP AND ELECTRICAL SPLICE COMPARTMENT." The co-pending
application Ser. No. 11/077,690, filed Mar. 10, 2005, and titled
"ELECTRICAL JUNCTION ASSEMBLIES FOR COUPLING ELECTRICAL FIXTURES TO
SUSPENDING CEILING GRIDS," and Provisional Patent Application Ser.
No. 60/552,464, filed on Mar. 11, 2004, and titled "INTEGRATED TEE
BAR CLIP AND ELECTRICAL SPLICE COMPARTMENT" are both hereby
incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to systems, devices for and methods of
mounting and electrically coupling electrical fixtures to ceiling
structures. More particularly, the present invention relates to
systems, management systems, and devices for and methods of
mounting and electrically coupling fixtures to suspended ceiling
grids.
BACKGROUND
[0003] Modem offices and schools often employ false, drop or
suspended ceilings. A Suspended ceiling includes a grid of T-bar
structures that support removable ceiling tiles. The T-bar
structures are typically secured to a stable building structure,
such as an I-beam, a fixed ceiling or a wall through wires that
support the weight-bearing load of the T-bars and the removable
ceiling tiles. The T-bar structures also provide locations for
securing mounting assemblies that cans be used to suspend
electrical fixtures.
[0004] Typically mounting assemblies that attach to T-bar
structures are also typically secured to a stable building
structure to help distribute the weight bearing of an electrical
fixture suspended.
SUMMARY
[0005] The present invention is directed to T-bar clip assemblies
and methods. A T-bar clip assembly, in accordance with the
embodiments of the invention, is configured to securely couple to a
T-bar member with a vertical support structure and horizontal
support flanges that can also be described as having a
substantially T-shaped cross section. T-bar structures are
installed in an inverted fashion construct grids that support
removable ceilings that rest on the horizontal support flanges with
the vertical support structures extending upwards and that recede
into the outer surface of the suspended ceiling.
[0006] A T-bar clip assembly is configured to support an electrical
fixture, generally a light fixture, securely coupled to a T-bar
structure. A T-bar clip assembly, in accordance with the
embodiments of the invention, includes at least one junction box
that has an aperture configured to receive and secure to a piece of
standard flexible or rigid conduit with power lines. The junction
box also is configured to provide at least one power feed directly
out of the junction box to provide power to the electrical fixture
supported therefrom. Preferably, the power feed is flush with an
outer surface of a removable ceiling tile, an outer edge of the
support flanges of the T-bar structure, or both, such that little
no or insulating hardware is required above the removable ceiling
tile in order to properly install the electrical fixture.
[0007] In accordance with the embodiments of the invention, a T-bar
clip comprises support brackets that secure around a T-bar
structure and one or more housing structures. Preferably, the one
or more housing structures couple with at least one of the support
brackets and together they form a junction box enclosure that is
recessed above the suspended ceiling grid. The junction box
enclosure provides a one or more locations for electrical
connections and at least one power feed location out of the
junction box that is substantially flush with support flanges of
the T-bar structure.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIGS. 1A-B show schematic representations of a prior art
T-bar clip assembly.
[0009] FIG. 2 shows a schematic representation of a prior art T-bar
clip assembly with an adjustable bracket.
[0010] FIG. 3 is an exploded view of a T-bar clip assembly, in
accordance with the embodiments of the invention.
[0011] FIG. 4 shows a partial cross-sectional view of a T-bar clip
assembly mounted flush with a surface of a suspended ceiling, in
accordance with the embodiments of the invention.
[0012] FIG. 5 is a schematic of power lines supported within a
T-bar clip assembly, in accordance with the embodiments of the
present invention.
[0013] FIG. 6 shows a perspective view of a T-bar clip assembly for
use with two power feed locations, in accordance with the
embodiments of the present invention.
[0014] FIG. 7 shows a perspective view of a T-bar clip assembly, in
accordance with further embodiments of the invention.
[0015] FIG. 8 shows a perspective view of a T-bar clip assembly, in
accordance with yet further embodiments of the invention.
[0016] FIG. 9 shows a perspective view of a T-bar clip assembly, in
accordance with yet further embodiments of the invention.
DETAILED DESCRIPTION
[0017] FIG. 1A shows side cross-sectional view of a prior art T-bar
clip assembly 100 for mounting and suspending an electrical fixture
(not shown) from a T-bar structure 106 that is used to form a T-bar
grid that supports suspended ceiling tiles (not shown). The T-bar
structure 106 has a vertical support 16 and horizontal flanges 114
for supporting removable ceiling tiles (not shown). The T-bar clip
assembly 100 includes a first mounting bracket 101 and second
mounting bracket 103 a that are clamped together and around the
T-bar structure 106. A bolt feature 104 is attached to at least one
of the first mounting bracket 101 and the second mounting bracket
103 therefrom.
[0018] In order to install the T-bar clip assembly 100, the first
mounting bracket 101 is fitted up to the T-bar structure 106. The
second mounting bracket 103 is moved in a direction indicated by
the arrow 110 to clamp around the T-bar structure 106, such as
shown in FIG. 1B, and are secured together through a suitable
clamping means 107. The first mounting bracket 101 and the second
mounting bracket 103 are then securely held in position around the
T-bar structure 106 using a bolt or any other suitable securing
feature (not shown). A wire or other feature 105 can be attached to
a top portion of the T-bar clip assembly 100. The wire or other
support feature 105 is used to couple the T-bar clip assembly 100
to a stable building structure, such as an I-beam or a permanent
ceiling, and to support the weight-bearing load of an electrical
fixture attached to the T-bar clip assembly 100 through the bolt
104.
[0019] A T-bar clip assembly, such as the T-bar clip assembly 100
described above with reference to FIG. 1A and FIG. 1B, has several
shortcomings. The T-bar clip assembly 100 is not adaptable for use
with different-sized T-bars, such as T-bars having different
heights and/or different widths. Further, the T-bar clip assembly
100 does not provide any features to support electrical connections
123 and 125 or wiring 121 required to power the electrical fixture
attached to and supported from the T-bar clip assembly. A power
feed location can be provided by vertically mounting a junction box
111 to one of the mounting brackets 101 and 103. However, typically
only one junction box 111 can be mounted to the T-bar clip assembly
100. Further, the junction box 111 can not be mounted to the T-bar
clip assembly 100 with the junction box 111 flush with a surface of
a suspended ceiling as indicated by the dotted line 117.
Accordingly, an insulator coupler or sleeve 119 must be installed
to span the distance D1 between the junction box 111 and the
surface of the suspended ceiling 117. Even when the T-bar clip
assembly 100 is installed with the insulating coupler or sleeve
119, such installation of the T-bar clip assembly 100 may be not be
acceptable or allowed by local or national electrical codes and
regulations.
[0020] Bulvan et al. in U.S. Pat. No. 6,464,179 describes an
improved T-bar clip assembly 200, illustrated in FIG. 2, for
securing to a T-bar structure 206 that can then be used for
mounting and suspending an electrical fixture from the T-bar
structure 206, such as described above. The T-bar clip assembly 200
is more versatile than the T-bar clip assembly 100, described
above, and is capable of securing to and clamping around a large
range of sizes of T-bar. The T-bar clip assembly 200 includes a
first mounting bracket 201 and a second mounting bracket 203 that
secure around the T-bar structure 206. The first mounting bracket
201 and the second mounting bracket 203 are coupled to adjustable
bracket 215 that is used to adjust the vertical position of the
T-bar clip assembly 200. When the T-bar clip assembly 200 is
installed, the adjustable bracket 215 is coupled to the T-bar clip
assembly 200 through a bolt 204. A wire or other feature 205 can be
attached to a top portion of the T-bar clip assembly 200 and
support the weight-bearing load of an electrical fixture attached
to the T-bar clip assembly 200. A power feed location can be
provided by vertically mounting a junction box 211 to positions 213
and 217 on the adjustable bracket 215. Rigid or flexible conduit
221 with electrical lines 223 and 225 can be fed into the junction
box 211 for hardwiring the electrical fixture. As with the T-bar
clip assembly 100, only one junction box 111 can be mounted to the
T-bar clip assembly 200 and because the junction box 211 cannot be
mounted flush with a surface of a suspended ceiling, an insulator
coupler or sleeve 219 must be installed to span the distance
between the junction box 211 and the surface of the suspended
ceiling. Accordingly, there is a need for a T-bar clip assembly
that can be used for mounting and suspending an electrical fixture
and that addressees the aforementioned shortcomings.
[0021] FIG. 3 shows an exploded view of a T-bar clip assembly 300
in accordance with the embodiments of the invention. The T-bar clip
assembly 300 includes support brackets 301 and 303 for securing
around a T-bar structure 401 of a suspended ceiling grid to form a
vertical housing support 350. The support bracket 301 can include a
mounting aperture 316 that mates with a mounting tab 314 on the
support bracket 303 for aligning the support brackets 301 and 303
in a position around the T-bar structure 401. After the support
brackets 301 and 303 are aligned, the support brackets 301 and 303
can be secured together to the position around the T-bar structure
401 using screws 321 and 322 that are screwed through mounting
apertures 312 and 313. It will be clear to one skilled in the art
that the support brackets 301 and 303 can be secured together and
to the position around the T-bar structure 401 using any suitable
securing means including, but not limited to, clips, nuts and
bolts, geometric mating features and any combination thereof.
[0022] Still referring to FIG. 3, the support brackets 301 and 303
can include flanges 311 and 331 that can be folded or bent down
from a retracted position, as shown with respect to the support
bracket 303, to an extended position, as shown with respect to
support bracket 301. The flanges 311 and 331 preferably have
receiving apertures 312 and 332 or pop-out structures (not shown)
that can be removed to provide the receiving apertures 312 and 332.
The receiving apertures 312 and 332 are preferably sized to couple
to flexible or rigid conduit, such as shown in FIG. 6, which
provide power lines to power an electrical fixture or fixtures (not
shown) coupled to the T-bar clip assembly 300. The support brackets
301 and 303 can also include means for securing to a building
support. For example, the support brackets 301 and 303 have wire
apertures 319 and 320 for receiving a wire 402 that can be attached
to a building support structure.
[0023] In accordance with a preferred embodiment of the invention,
the T-bar clip assembly 300 includes a housing structure 302 that
is configured to couple to the vertical housing support 350 and
from a junction box enclosure, such as shown in FIG. 6. In
accordance with this embodiment of the invention, the flanges 311
form a top portion of the junction box enclosure when the housing
structure 302 is attached to the vertical housing support 350. The
housing structure 302 can be coupled to the vertical housing
support 350 through one or more screws 321 and corresponding
mounting tabs 315 and/or any other suitable means including, but
not limited to, clips, nuts and bolts, geometric mating features
and any combination thereof. The housing structure 302 can also
include a slotted feature 310 that receives a matched flange tab
318 of the flange 311. With the housing structure 302 attached to
the vertical housing support 350, at least one of the support
brackets 301 and 303 and the resultant junction box enclosure
provides a location for splices and electrical service connections
to electrically couple the electrical fixture or fixture to the
power lines and at least on power feed location from a bottom
portion 309 of the housing structure 302.
[0024] At least one of the support brackets 301 and 303 preferably
includes a stud structure 308, or any other attachment means, for
coupling to a fixture hardware kit 339 and for supporting a light
fixture. The fixture hardware kit 339 can include, for example, a
canopy 304, 15 that covers any exposed portions of the T-bar clip
assembly 300, a sleeve 307, fix receiving power lines from the
junction box enclosure, and a bushing 305 with a support wire 306
that attaches to the stud structure 308 or other attachment means
for supporting the weight bearing load of the light fixture.
[0025] FIG. 4 shows a partial cross-sectional view of an installed
T-bar clip assembly 400, in accordance with the embodiments of the
invention. The housing structure 302 is coupled to the support
bracket 301 that is attached to the T-bar structure 401 and is
preferably attached to the T-bar structure 401 such that the
support bracket 301 is vertically positioned and substantially
parallel with the vertical support 405 of the T-bar structure 401.
The housing structure 302 and the support bracket 301 form the
junction box enclosure 411 that provides at least one power feed
409 with power lines to power an electrical fixture, such as
described in detail above. Preferably, the power feed 409 exits the
junction box enclosure 411 at a location at a bottom portion 413 of
the junction box enclosure 411, wherein the location is
substantially even with or flush with the outer surface 415 of a
removable ceiling tile 409, a horizontal support flange 407 of the
T-bar structure 401 or both. As described above, the T-bar clip
assembly 400 is configured to couple to a fixture hardware kit that
can include a canopy structure 304, for covering exposed portions
of the T-bar clip assembly 400, and a sleeve structure 307, for
receiving power lines from the power feed 409, exiting the bottom
portion 413 of the junction box enclosure 411.
[0026] FIG. 5 shows a perspective view 500 of a housing structure
303, in accordance with the embodiments of the invention.
Like-numbered elements in FIGS. 5 and 3 refer to similar elements.
The housing structure 303 includes power feed support flanges 309
and 309' to support a power feed line 409 with power wires 421 and
423 contained therein. The power feed line 409 can be supported by
the power feed support flanges 309 and 309' with a grommet
structure 417, a knot or any other structure that helps prevent the
power feed line 409 from being pulled through the support flanges
309 and 309'.
[0027] FIG. 6 shows a perspective view of a T-bar clip assembly 600
coupled to a T-bar clip structure 401, in accordance with further
embodiments of the invention. Again, like-numbered elements in
FIGS. 6 and 3 refer to similar elements. The T-bar clip assembly
600 includes a first housing structure 302 and a second housing
structure 302' that are configured to be coupled to a vertical
housing support 350. The vertical housing support 350 can be formed
form a first housing support bracket 301 and a second housing
support bracket 303, wherein the first housing structure 302 and
the first housing support bracket 301 form a first junction box
enclosure 411 and the second housing structure 302' and the second
housing support bracket 303 form a second junction box enclosure
411'. Each of the first junction box enclosure 411 and the second
junction box enclosure 411' is configured to couple to conduits 403
and 403' through top portions 311 and 311' of the junction box
enclosures 411 and 411', respectively. As described above the top
portions 311 and 311' of the junction box enclosures 411 and 411'
can be formed from flange structures that extend outward from the
first housing support structure 301 and the second housing support
structure 303, respectively. Each of the junction box enclosures
411 and 411' provide power-feed location through bottom portions of
the junction box enclosure 411 and 411', as described above.
Preferably, the power feed locations are even with or flush with an
outer surface of a removable ceiling tile, a horizontal support
flange 407 of the T-bar structure 401 or both. The T-bar clip
assembly 600 is configured to couple to multiple electrical
fixtures through an electrical fixture hardware kit 339' that can
include a canopy 304, for covering exposed portions of the T-bar
clip assembly 600, sleeves 307 and 307', for receiving power lines
from power feeds exiting the junction box enclosures 411 and 411',
and a bushing structure 305 with a support wire 306 for coupling to
the T-bar clip assembly 600 and supporting the weight-bearing load
of electrical fixtures attached thereto. Also, the T-bar clip
assembly 600 can be coupled to a wire support 402 that is attached
to a building structure.
[0028] FIG. 7 shows a T-bar clip assembly 700, in accordance with
further embodiments of the invention. The T-bar clip assembly 700,
includes a first housing support structure 701 and a second housing
support structure 703 that are configured to secure around a T-bar
structure (not shown) and provide a vertical housing support
structure 750, such as described above. The T-bar clip assembly 700
also includes a housing structure 702 configured to couple to the
vertical housing support structure 750 through any suitable means
and form a junction box enclosure. The junction box enclosure is
configured for providing one or more power feeds that exit the
junction box enclosure at a position that is even with or flush
with a suspended ceiling (i.e. a T-bar structure and/or removable
ceiling tile.) A housing structure 702 preferably includes a top
portion 711 with an aperture 712 configured to couple to conduit,
which provides power lines into the junction box enclosure.
[0029] FIG. 8 shows a T-bar clip 800, in accordance with yet
further embodiments of the invention. The T-bar clip assembly 800
includes a first housing support structure 801 and a second housing
support structure 803 that are configured to secure around a T-bar
structure (not shown) and provide a vertical housing support
structure 850, such as described above. The T-bar clip assembly 800
also includes a housing plate 802 configured to attach to an
integral housing structure 807 of the first housing support
structure 801 and form a junction box enclosure. The junction box
enclosure is configured for providing one or more power feeds that
exit the junction box enclosure at a location that is even with or
flush with a suspended ceiling. The integral housing structure 807
preferably includes a top portion 811 with an aperture 812
configured to couple to a conduit that provides power lines into
the junction box enclosure.
[0030] FIG. 9 shows a T-bar clip assembly 900, in accordance with
still further embodiments of the invention. Again, like-numbered
elements in FIGS. 8 and 3 refer to similar elements. The T-bar clip
assembly 900, includes housing support structure 901 and a T-bar
clip feature 906 configured to secure around the T-bar structure
401. The housing support structure 901 is coupled to the T-bar clip
feature 906 to form a vertical housing support structure. The
housing support structure 901 is coupled to the T-bar clip feature
906 through a screw 924 or any other suitable attachment feature
including, but not limited to, clips, nuts and bolts, other
geometric mating features and any combination thereof. The T-bar
clip assembly 900 also includes a housing structure 902 configured
to couple to the housing support structure 901 and form a junction
box enclosure. The junction box enclosure is configured to provide
one or more power feeds even with or flush with a suspended
ceiling. The housing support structure 901 can include a flange 911
that forms a top portion of the junction box enclosure with the
housing structure 902 coupled to the housing support structure 901.
The flange 911 can include an aperture 912 configured to couple to
the conduit that provides power lines into the junction box
enclosure.
[0031] The present invention has been described in terms of
specific embodiments incorporating details to facilitate the
understanding of the principles of construction and operation of
the invention. As such, references, herein, to specific embodiments
and details thereof are not intended to limit the scope of the
claims appended hereto. It will be apparent to those skilled in the
art that modifications can be made in the embodiment chosen for
illustration without departing from the spirit and scope of the
invention.
* * * * *