U.S. patent number 3,690,243 [Application Number 05/133,284] was granted by the patent office on 1972-09-12 for suspended ceiling framework supported troffer air distribution system.
This patent grant is currently assigned to Air Factors, Inc.. Invention is credited to Robert R. Lambert.
United States Patent |
3,690,243 |
Lambert |
September 12, 1972 |
SUSPENDED CEILING FRAMEWORK SUPPORTED TROFFER AIR DISTRIBUTION
SYSTEM
Abstract
The suspended ceiling framework supported troffer air
distribution system has effectively continuous arrays or rows of
resilient inverted channel members, each having the lower feet
thereof separated in a natural state, and contracted for insertion
on and between the runners of a suspended ceiling framework and
over air control means extending between the runners; and has
ceiling tile inserted between the runners and the air control means
to close the channel members for conducting air therealong. The
inverted channel members may be integral; assembled from separate
sides, and a web; or folded from duct board which is longitudinally
notched and which is with or without lower foot channels. The duct
board may also be longitudinally notched to provide marginal side
portions which extend from the runners to the air control means
when the duct board is mounted on the suspended ceiling framework.
As additional support and to relieve the weight on the suspended
ceiling framework, anchors and clamped longitudinal members may
secure the channel members and transverse members to with and
between the soffit wires hanging the framework. Each array or row
may have channel members of uniform side heights or may have
channel members of descending side heights from a cross duct. The
cross ducts may be located in staggered relationship between the
troffer rows.
Inventors: |
Lambert; Robert R. (Glendora,
CA) |
Assignee: |
Air Factors, Inc. (Redlands,
CA)
|
Family
ID: |
22457855 |
Appl.
No.: |
05/133,284 |
Filed: |
April 12, 1971 |
Current U.S.
Class: |
454/303;
52/506.07 |
Current CPC
Class: |
F24F
13/0254 (20130101); F24F 13/072 (20130101); E04B
2009/026 (20130101) |
Current International
Class: |
F24F
13/02 (20060101); F24F 13/072 (20060101); F24F
13/06 (20060101); E04B 9/02 (20060101); F24f
013/06 () |
Field of
Search: |
;98/4D,4DL,4C
;52/221,484 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Wayner; William E.
Claims
I claim:
1. A suspended ceiling framework supported troffer air distribution
system for use with a suspended ceiling framework of main and cross
inverted T-bar runners, having air control means mounted between a
first pair of runners and extending parallel to, but spaced from,
an adjacent second pair of runners, comprising:
an inverted channel member mounted to and between the adjacent
second pair of runners over the air control means and
blocking means extending between the runners and the air control
means for closing the space therebetween to provide a conduit for
conducting conditioned air to the air control means.
2. The invention as in claim 1 wherein the channel member is made
of a resilient material, and is provided with lower feet which are
separated in a natural state, by a distance greater than spacing
between the second pair of runners, said lower feet being
contracted for insertion between the second pair of runners whereby
the resilience of the member maintains the channel member mounted
between the second pair of runners.
3. The invention as in claim 2 wherein the channel member includes
upturned edges extending outwardly and upwardly from the lower
feet, said edges gripping the T-bar runner to mount the channel
member.
4. The invention as in claim 1 wherein the channel member is formed
of separable sides and a web, said web having formed edges opening
downwardly which mate with the upper edges of the sides to form the
channel member.
5. The invention as in claim 4 wherein the sides are provided with
lower feet, wherein the web edges open slightly outwardly to
separate the lower feet of the sides a distance greater than the
spacing between the second pair of runners, and thereby bias the
feet into the runners and hold the web to the sides.
6. The invention as in claim 1 wherein the blocking means includes
ceiling tile located between the runners and the air control
means.
7. The invention as in claim 6 wherein said ceiling tiles are
ceiling tile removed from a space enclosed by the main and cross
runners to mount the air control means, said removed ceiling tile
being cut into a suitable shape for reinsertion between the runners
and the air control means.
8. The invention as in claim 1 wherein the channel member includes
a section of ductboard formed in an inverted U-shape.
9. The invention as in claim 8 wherein the ductboard has lower
edges
and wherein foot channels are provided for receiving the lower
edges of the ductboard and for mounting to and between the adjacent
second pair of runners.
10. The invention as in claim 9 wherein the foot channels each
include
an upwardly opening U-shaped cross section portion for receiving
and holding the lower edge of the ductboard, and
an offset foot portion extending downwardly from the U-shaped cross
section portion to seat on the flange of the second runner, said
foot portion having an upper edge extending under the head ridge of
the second runner to hold the foot channels to the second pair of
runners.
11. The invention as in claim 8 wherein the section of ductboard is
initially flat, said ductboard section being longitudinally notched
for folding into a channel.
12. The invention as in claim 11 wherein the ductboard section has
additional longitudinal notches located parallel to the side edges
to provide marginal side portions, said marginal side portions
being folded inwardly between the runners and the air control means
when the ductboard is mounted on the second pair of runners.
13. The invention as in claim 12 wherein the ductboard section has
an inner ductboard layer which is longitudinally notched, and an
outer covering layer, said covering layer being visible from below
the framework when the marginal side portions extend between the
runners and the air control means.
14. The invention as in claim 1 additionally comprising additional
support means for additionally supporting the inverted channel
member.
15. The invention as in claim 14 wherein the framework includes
soffit wires hanging from the ceiling and wherein the additional
support means holds the channel member to a soffit wire to be
additionally supported thereby.
16. The invention as in claim 15 wherein the additional support
means includes clamping means around the soffit wire and secured to
the channel member to provide the additional support.
17. The invention as in claim 16 wherein the clamping means
includes the provision of a hole in the side wall of the channel
member adjacent the soffit wire and wherein the anchor includes a
hook extending around the soffit wire and into the hole to be
secured therein to secure the channel member to the wire.
18. The invention as in claim 16 wherein the additional support
means includes a transverse member extending between adjacent
soffit wires and located on the inverted channel member, said wire
anchors pulling the soffit wires together against the member to
provide lateral support.
19. The invention as in claim 15 wherein the additional support
means includes longitudinal members extending between adjacent
soffit wires along the channel member, at least one end of said
longitudinal member being suitably shaped to receive a soffit wire
therein, and includes clamping means on said one end for clamping
the soffit wire so received to the longitudinal member to provide
longitudinal member provide longitudinal support.
20. The invention as in claim 19 wherein the longitudinal member is
U-shaped and opening outwardly with the one end thereof having
aligned notches for receiving the soffit wire, and wherein the
clamping means includes a clamping member sized to fit within the
longitudinal member over the soffit wire and includes a fastener
between the longitudinal member and the clamping member to draw the
two together to bend the soffit wire inwardly, and mount the
longitudinal member to the soffit wire.
21. The invention as in claim 1 wherein a plurality of air control
means are provided to form a linear, effectively continuous, air
control means; and wherein a plurality of channel members and
plurality of blocking means are provided to form a linear,
effectively continuous, troffer array to conduct conditioned air
along the continuous air control means.
22. The invention as in claim 21 additionally comprising a
transverse wall across the end of the troffer array to close that
end.
23. The invention as in claim 21 wherein the channel members of a
troffer array have sides of uniform height.
24. The invention as in claim 21 wherein the channel members of
troffer array have a cross-section which is reduced as the channel
members extend in opposite directions from a given channel member
to compensate for the upstream flow of air through the air control
means.
25. The invention as in claim 24 wherein the channel members of a
troffer array have sides of descending heights, extending in
opposite directions from the given channel member to provide a
progressively reduced cross-sectional area.
26. The invention as in claim 21 wherein a parallel pair of troffer
arrays are provided, and wherein a cross duct extends between the
troffer arrays to provide conditioned air, and a vane unit is
provided at the juncture of the duct with each array to direct the
conditioned air supplied by the cross duct down the arrays.
27. The invention as in claim 21 wherein at least five parallel
troffer arrays are provided, wherein a transverse wall is centrally
located in each array to provide array halves, and wherein a cross
duct is provided between adjacent array halves to supply
conditioned air thereto.
28. The invention as in claim 27 wherein the cross ducts are in
staggered relationship between arrays except for the end
arrays.
29. A method of installing a troffer air distribution system in a
suspended ceiling framework of main and cross inverted T-bar
runners having an air control means mounted between one pair of
runners and extending parallel to, but spaced from, an adjacent
other pair of runners, comprising the steps of:
providing a channel member with side flanges between which a web
extends,
inverting the channel member
mounting the inverted channel member on and between a pair of
spaced runners over the air control means, and
inserting a blocking means between said runners and the air control
means therebetween to provide an air conduit.
30. The method of claim 29
wherein the step of providing a channel member with side flanges
includes providing said member with side flanges having the lower
feet thereof spread apart, in a natural state a distance greater
than the spacing between the pair of runners, and
wherein the step of mounting the inverted channel member includes
the steps of contracting the feet of the channel member, inserting
the feet between the pair of runners, and releasing the feet to
mount the channel member to the runners.
31. The method as in claim 29
wherein the step of providing a channel member includes the steps
of providing sides and a web, and
wherein the step of mounting the channel member includes the steps
of mounting the sides on the runners, and mounting the web to the
sides so mounted to the runners.
32. The method as in claim 29 wherein the step of providing a
channel member additionally includes the step of
inserting each lower edge of the folded ductboard section into a
lower foot channel to complete the channel member.
33. The method as in claim 29
wherein the step of providing blocking means includes the step of
providing ceiling tile of a suitable size, and
wherein the step of inserting a blocking means includes the step of
inserting the ceiling tile in the space between the sides of the
air control means and the adjacent runners.
34. The method as in claim 29 wherein the step of providing a
channel member includes the steps of
providing a flat duct board section,
longitudinally notching the duct board section, to facilitate
folding into a channel member, and
folding the ductboard section into a channel member.
35. The method as in claim 33 wherein the step of providing a
channel member includes the steps of
providing a flat duct board section having a covering layer along
one surface thereof,
longitudinally notching the board section on the opposite surface
suitably for folding into a C-shaped cross-section with marginal
side portions,
folding the section into a C-shaped cross-section, and
wherein the step of mounting the channel member and the step of
inserting the blocking means includes the step of
inserting the folded duct board between the runners with the
marginal side portions extending to the air control means to close
the space therebetween.
36. The method as in claim 29 additionally including the step
of
additionally supporting the channel member between the steps of
mounting the member and inserting a blocking means.
37. The method as in claim 36 wherein the step of additionally
supporting the channel member includes the step of clamping the
channel member to a soffit wire.
38. The method as in claim 37 wherein the step of supporting the
channel member includes the step of inserting a transverse member
between the soffit wires before the step of anchoring the channel
member to a soffit wire and wherein the step of clamping the
channel member to a soffit wire includes the step of pulling the
soffit wires against the ends of the transverse member to provide
lateral support.
39. The method as in claim 36 wherein the step of additionally
supporting the channel member includes the steps of
providing a longitudinal member along the channel member, said
longitudinal member having one end suitably shaped to receive a
soffit wire therein,
inserting the soffit wire into the one end of the longitudinal
member and
clamping the soffit wire to the longitudinal member to support the
channel member.
Description
BACKGROUND OF THE INVENTION
This invention relates to air distribution systems and more
particularly to such systems mounted on a suspended ceiling
framework.
The use of air supply ducts in an air distribution system is shown
in my copending application for U. S. Letters Patent, Ser. No.
815,835, filed Apr. 14, 1969, and entitled "Suspended Ceiling
Integrated Air Distribution System."
These ducts have been generally of a round or box-like cross
section with sides that merge into narrow neck portions which mount
directly onto the air diffuser assembly. In order to increase the
cross-sectional area of these ducts for increased air volume or for
decreased velocity for a given air volume, it is necessary to
increase the dimensions of the duct above the neck portions.
However, these ducts must still merge smoothly into the narrow neck
portions whose size is limited by the size of air diffuser
assembly. Even a duct of slightly increased size when mounted on a
narrow air diffuser assembly becomes very unstable and unwieldy. It
becomes readily apparent that the size of such a duct may not be
increased sufficiently to provide the air flow and volume need for
many jobs, without providing independent support for the enlarged
duct itself.
The immediate solution to the problem for supporting the enlarged
ducts that appears is to simply hang the duct from the real ceiling
or soffit by wires, just as the suspended ceiling framework is
hung. However, with such a solution, the wires must be anchored to
the real ceiling by working through the suspended ceiling, which
usually is already installed. The wires must be precisely located
on the real ceiling so as to align the ducts carried thereby with
the air diffuser assemblies carried by the ceiling framework, and
the ducts must be hung on the wires a precise distance below the
real ceiling so as to connect with the air diffuser assemblies
carried by the ceiling framework. With such precision required to
hang the enlarged ducts from the real ceiling, the cost,
installation time, etc. made this solution to the problem of
supporting the enlarged air ducts impractical for most air
distribution systems.
In more and more of the buildings requiring such enlarged air
troffers, a two foot by four foot suspended ceiling framework is
being installed below the real ceiling of the rooms in the
building. This framework divides the entire ceiling space into
rectangular spaces of two feet wide and four feet long defined by
main and cross inverted T-bar runners. The rectangular spaces
defined by the framework are each filled with ceiling tile which
rests on the lower flanges of the runners to complete of the
suspended ceiling. The use of conventional size air ducts over air
control means is ideally suited for the suspended ceiling as is
explained in my previously identified application. However, when an
enlarged air duct is required, the above-described problems in the
supporting of the enlarged air duct arise.
Additionally, it would be very desirable to initially provide
parallel rows of enlarged air ducts extending the entire width of
the ceiling over rows of air control means extending the entire
width of the ceiling. With the initial provision of such rows, only
the portions of the ducts and air control means needed, would be
used, but the entire length of such rows would be available for use
and when needed. However, the length of such rows would usually
require enlarged ducts and would create the afore-mentioned
problems in supporting such air ducts over such a length. What is
needed then is an improved air duct construction having a large
cross-sectional area and which can be easily, quickly and
inexpensively installed on a suspended ceiling framework to feed
air control means carried by the framework. After installation,
such a duct construction could at least be partially supported from
the real ceiling to relieve a portion of its weight from the
suspended ceiling framework where vibrations or ceiling movement
can be expected.
BRIEF DESCRIPTION OF THE INVENTION
Therefore, it is the primary object of this invention to provide an
improved suspended ceiling framework supported air distribution
system and method of installing such a system which overcomes the
various problems presented by, and limitations of, prior air
distribution systems as discussed hereinabove.
Generally stated, the improved air distribution system of the
present invention is adapted for use with a suspended ceiling
framework of main and cross inverted T-bar members having air
control means mounted between a first pair of runners and extending
parallel to, but spaced from, an adjacent second pair of runners,
and includes an inverted channel member or troffer mounted to the
adjacent second pair of runners over the air control means, and
blocking means extending between the adjacent second pair of
runners and the air control means for closing the space
therebetween to provide a troffer assembly for conducting
conditioned air to the air control means. The channel member or
troffer may be made of a resilient material with the side walls
initially spread apart to facilitate their retention between the
spaced runners when assembled therebetween. The free edges or feet
of the side walls may also have reverse bent, outwardly flared
resilient flanges which nest under the inverted T-bar head flanges
on said assembly. The channel member may be integrally formed;
assembled from separate sides and a web; or folded from a
longitudinally notched flat duct board section into a channel shape
with or without lower feet channels. The blocking means may be
removed ceiling tile, cut into a suitable shape or marginal side
portions of the duct board. Additional supporting means may be
provided for supporting at least part of the weight of the channel
members. The rows of channel members may have uniform side heights
or have descending side heights. The system may also include
parallel troffer rows connected by cross ducts in staggered
relationship.
Generally, the method of installing a troffer air distribution
system in a suspended ceiling framework of main and cross inverted
T-bar runners having air control means between one pair of runners,
and extending parallel to, but spaced from, an adjacent other pair
of runners includes the steps of providing a channel member with
side walls between which a web extends, inverting the channel
member, mounting the channel member on and between the adjacent
other pair of runners over the air control means and inserting a
blocking means between said runners and the air control means
therebetween to provide an air conduit. The step of mounting the
channel member may also includes the contracting of the channel
side walls, inserting of the channel feet or free edges between the
runners and then releasing the channel side walls. The step of
providing the blocking means may include the steps of providing a
ceiling tile of suitable shape and inserting the ceiling tile
between the runners and the air control means. The step of
providing the channel member and the step of providing the blocking
means may include the steps of providing a flat duct board section,
longitudinally notching the board section, folding the notched
section, inserting the folded section between the runner with the
marginal side portions extending to the air control means. The step
of additionally supporting the channel member may be added after
the step of mounting the member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a suspended ceiling framework
supported troffer air distribution system, according to this
invention, located in a rectangular space, defined by building
walls which are shown in phantom lines.
FIG. 2 is a side elevational view taken along the plane II--II of
FIG. 1 showing an effectively continuous array of troffers,
supplied by cross ducts which are in turn fed by vertical supply
ducts, shown in phantom lines.
FIG. 3 is a side elevational view similar to FIG. 2 but showing an
effectively continuous array of troffers having sides of descending
height from the individual troffer supplied by the cross duct.
FIG. 4 is an enlarged, broken away, plan view of the encircled
portion of FIG. 1, showing vanes dividing the air from the cross
ducts and directing the air, so divided down the air troffers.
FIG. 5 is an enlarged fragmentary perspective view of a portion of
a suspended ceiling, with the framework thereof mounting an air
troffer over an air diffuser assembly.
FIG. 6 is an end elevational vie of a suspended ceiling, showing in
solid lines a preferred embodiment of the air troffer over an air
diffuser assembly, with the free state position of the air troffer
edges shown in phantom lines, and showing in phantom lines over the
preferred embodiment an alternative embodiment three-part
construction of the air troffer.
FIG. 7 is a view similar to FIG. 6, but showing a second
alternative preferred embodiment of an air troffer constructed of a
covered duct board section.
FIG. 8 is a side elevational view of the covered duct board
section, prior to being folded into the air troffer, and
FIG. 9 is a fragmentary plane view taken along the plane IX--IX of
FIG. 6, showing the additional support means for supporting at
least a part of the weight of the air troffer, according to this
invention.
FIG. 10 is a view similar to FIGS. 6 and 7, but showing a third
alternative preferred embodiment of the air troffer,
FIG. 11 is a perspective view similar to FIG. 5 but shows the third
alternative preferred embodiment of the air troffer according to
this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS:
Referring now to the drawings and particularly to FIG. 1, the
suspended ceiling framework supported troffer air distribution
system is generally indicated by the number 10. The system 10 is
illustratively shown in a rectangular room 11, the walls of which
are shown by phantom lines. The room 11 contains a suspended
ceiling 12 constructed of a framework 13 which divides the ceiling
space into smaller spaces. The framework 13, as best seen in FIGS.
5, 6, and 7, includes main runners 14a and cross runners 14b of
inverted T-bar members each having a horizontal flange 15, a
vertical web 16 and a head ridge 17. The framework 13 is hung from
the real ceiling of the room 11 by soffit wires 18 which join the
framework 13 at the intersection of the main and cross runners 14a
and 14b. The illustrative suspended ceiling framework 13 is of the
commonly used two foot by four foot design, i.e. the framework 13
divides the ceiling space into rectangles approximately two feet
wide and four feet long. A ceiling tile 19 of a suitable
rectangular shape and size is inserted into each rectangular space
and rests on and between the horizontal flanges 15 of the runners
14.
The system 10 includes the provision of air control means 20
located in the suspended ceiling 12 to be supported by the
framework 13 thereof as is taugh in my previously identified
co-pending patent application. The air control means 20
illustratively shown in FIGS. 1, 4, 5, 6, and 7 is an air diffuser
assembly 21, though other air control means 20 could be used, as
required.
The air diffuser assembly 21 as taught by my copending patent
application is constructed of spaced inverted T-bar members 22,
each having a horizontal flange 23, a vertical web 24, an inside,
upwardly extending rib 25 in the flange 23 and spaced from the web
24, and a head ridge 26 with an upwardly opening longitudinal
groove 27. Weir supporting inverting channels 28 have the lower
edges thereof inserted in the space between the ribs 25 and the
vertical webs 24 to seat on the horizontal flanges 23 of the
inverted T-bar members 22. The webs of the channels 28 space the
members 22 and support a nested pair of weir members 29 as is
taught by my U.S. Pat. No. 3,411,425. Plates 30 extend under the
head ridges 26 to abut the vertical webs 24 and space them apart
while retaining the nested weir members 29 on the channels 28. The
r diffuser assembly 21 is completed by the provision of an
extractor channel 31 with the lower edges thereof located in the
grooves 27 of the head ridges 26 while the perforated web thereof,
having extractor vanes 32, is centrally located over and between
the spaced inverted T-bar members 22. Illustratively, the air
diffuser assembly 21 is shown extending between main runners 14a
and is shown centrally located between cross runners 14b. However,
the assembly 21 could be located closely adjacent the cross runners
14b or could incorporate a cross runner 14b as one of the spaced
inverted T-bar members 22 thereof.
Generally, the suspended ceiling supported troffer air distribution
system 10, according to this invention, includes an inverted
channel member or troffer 40 for mounting the adjacent cross
runners 14b over the air control means 20, and blocking means 90
for extending between the runners 14 and the air control means 20
for closing the space therebetween to provide a troffer subassembly
for conducting conditioned air. The individual members 40 and
blocking means 90 may be combined into effectively continuous
arrays or rows 95, and combined with other ducts to form a troffer
system. Additional support means 70 may be provided for supporting
part of the weight of the members 40.
The suspended ceiling supported troffer air distribution system 10
is shown in four embodiments of individual members 40 blocking
means 90, and two embodiments of the combined system 10. FIGS. 5
and 6 show a preferred embodiment of the individual channel members
40 and blocking means 90; FIG. 5 in phantom lines shows a first
alternative preferred embodiment of the member 40; FIGS. 7 and 8
show second alternative preferred embodiment of the individual
channel members 40 and blocking means 90; FIG. 10 and 11 show a
third alternative preferred embodiment of the individual channel
members; FIG. 2 shows a preferred embodiment of the system 10; FIG.
3 shows an alternative preferred embodiment of the system 10 and
FIGS. 1, 4, and 9 show views which may be common to all
embodiments.
Referring now to FIGS. 5 and 6, the preferred embodiment of the
inverted channel member or troffer 40 includes a channel 41 having
sides 42 between corresponding upper edges of which a web 43
extends. The side walls 42 have lower free edges or feet 44, with a
reverse bent or upturned edges of flanges 45. The channels 41 are
preferably made of a resilient material, such as sheet metal, and
the lower feet 44 thereof are separated in a natural state, as is
shown in phantom lines in FIG. 6, a distance greater than the width
between the webs 16b of the cross runners 12b. Such separation of
the feet 44 permits the inverted channel members 40 to be stacked
for shipment. The length of a channel 41 will be typically the
center to center distance between the soffit wires 18. The channel
41 has a centrally located lower notch 46 to extend over the main
runner 14a. The abutting juncture of adjacent ends of the channels
41 will be closed and sealed with tape 47, as will the notch 46 --
main runner 14a juncture.
To install the channels 41, in the framework 13, the channel 41 is
passed through the framework 13 into the attic space thereabove.
The channel 41 is then inverted and the lower feet 44 contracted
for insertion between the vertical webs 16b of the cross runners
12b and the notch 46 aligned over the appropriate main runner 14a.
When the lower feet 44 of the inverted channel 41 are adjacent the
horizontal flanges 15b, the feet 44 are released, permitting the
resilience of the channel 41 to spread the feet 44 and locate the
upturned edges 45 under the head ridges 17b to hold the channel 41
on and to the ceiling framework 13 over the air diffuser assembly
21.
The blocking means 90 of the preferred embodiment are the ceiling
tiles 19 which were removed from the framework 13 to mount the air
diffuser assembly 21 and which now have been cut or otherwise
shaped into two ceiling tiles 91 sized for insertion into the space
between the runners 14 and the inverted T-bar members 22 of the air
diffuser assembly 21. The ceiling tiles 91 are inserted just as
were the ceiling tiles 19 and seat on the flanges 15 and 23 to
close the inverted channel 41 and thereby provide a troffer for
conducting conditioned air to the air diffuser assembly 21.
If it is deemed advisable, once the inverted channel members 40 are
installed in the framework 13, additional support means 70 may be
provided for additionally supporting the channel members 40 and for
relieving at least a portion of the weight of the channel members
40 from the framework 13. In the preferred embodiment, the
additional support means 70 including the provision of a transverse
member 71 extends between the soffit wires 18 over the webs 42 of
the channel members 41. The additional support means also includes
the provision of clamping or anchoring means 80 for holding the
members 71 between the soffit wires 18. The means 80 of the
preferred embodiment are hooks 81, each having a curved or hook
shaped end 82 and a threaded end 83. A small hole 84 is punched in
the side 43 of the inverted channel members adjacent a soffit wire
18 for receiving the threaded end 83 of the hook 81. A sealing nut
85 is threaded thereto to close the hole 84 and draw the hook end
82 tightly around the soffit wire 18.
The hook 81 secures the channel member 40 to the soffit wire 18 and
pulls the wire 18 against the ends of the transverse member 71 to
provide lateral support to the channel 40. The nut 85 closes the
hole 84 to prevent the conditioned air carried in the troffer from
escaping therethrough.
Referring now to the phantom lines above the solid lines of FIG. 6,
the first alternative embodiment of the inverted channel member 40
includes the provision of the web 43 and sides 42 as separate
pieces. The web 43 is provided with downwardly opening, U-shaped
edges 50 which receive the upper edges 51 of the sides 42 to form
the channel members 40. The U-shaped edges 50 should open slightly
outwardly to spread the feet 44 of the sides 42 as before. The rest
of the sides 42 is the same as before to provide the troffer.
The first alternative embodiment of the channel member 20 is
assembled in the framework 13 by locating the sides 42 on the cross
runners 14 and snapping the side edges 50 of the web 42 over the
upper edges 51 of the sides 42 to construct the inverted channel
members 40 in the framework 13 itself. The big advantage of the
first alternative embodiment is that the sides 42 and web 43 may be
shipped to the job site flat, and thereby saving shipping space.
The additional support means 70, if required, will be installed
just as before.
Referring now to FIGS. 7 and 8, the second alternative preferred
embodiment of the inverted channel member 40 and the blocking means
90 includes the provision of a generally rectangular, flat, covered
duct board section 55. The duct board section 55, as seen in FIG. 8
has a duct board layer 56 and a vinyl covering layer 57 therebelow.
The duct board layer 56 is provided with a pair of longitudinally
extending notches 58 suitably spaced to permit the duct board layer
56 to be folded into the channel member 40 and a pair of
longitudinally extending notches 92 suitably spaced to permit the
duct board section 55 to be folded to provide marginal side
portions 93. The marginal portions 93, so provided, are generally
the same size and shape of the cut ceiling tile 91 to provide the
blocking means 90. The sections 55 will have open ended slots cut
therein, which when the sections 55 are folded, will provide the
equivalent of notches 46 for receiving the vertical webs 16a and
head ridges 17a, of the main runners 14a therein. The juncture
therebetween is closed by tape 47.
The second alternative preferred embodiment is constructed by
cutting a rectangular vinyl covered duct board section 55 from a
supply of vinyl covered duct board, cutting the longitudinally
extending notches 58 and 93 in the duct board layer 56 as shown in
FIG. 8, and folding the section 55 into a C-shaped cross section as
shown in FIG. 7. The section 55 so folded is inserted through the
framework 13 into the attic space thereabove, probably by
permitting the section 55 to unfold slightly. Once the duct board
section 55 is above the ceiling framework 13, the section 55 is
repositioned into the C-shaped cross-section, with the elongated
opening so formed, directed downwardly, and the section 55 is
lowered until the section 55 rests on the horizontal flanges 15
between the vertical webs 16. In this position the marginal side
portions 93 extend from the vertical webs 16b of the framework 13
to the vertical webs 24 of the air control means 20 and rest on the
horizontal flanges 23 of the inverted T-bar members 22. The
additional supporting means 70 may be installed, if needed, through
the ends of the sections 55 before the next section 55 is
installed. Upon complete installation of the sections 55, the vinyl
covering layer 57 will be visible from below to complete the
ceiling 12 while the duct board layer 56 provides the troffer for
conducting conditioned air to the air diffuser assembly 21.
Referring now to FIGS. 10 and 11, the third alternative preferred
embodiment of the inverted channel member or troffer 40 includes
the provision of a generally flat rectangular ductboard section 55
having only the ductboard layer 56. This ductboard section 50 is
provided with a pair of longitudinally extending notches 58
suitably spaced to permit the ductboard section 55 to be folded
into an inverted channel member 40 which has lower edges 59 which
could rest on and between the cross runners 14b. However, foot
channels 60 have been provided for receiving the lower edges 59 and
for mounting to and between the cross runners 14b.
The foot channels 60, each include an upwardly opening channel
portion 61 sized to receive a lower edge 59 therein with an
interference fit. The side walls of the channel portion 61 have
punched therein downwardly pointing teeth 62 which extend into the
ductboard layer 56 adjacent the lower edges 59 to hold the lower
edges 59 within the foot channels 60. The foot channels 60, each
also have an off-set foot portion 63 with a lower edge 64 for
resting on a flange 15b adjacent the web 16b of the cross runners
14b. An upper edge 65 is provided on the foot portion 63 for
extending under the head ridge 17b of the cross runners 14b. The
upper and lower edges 65 and 64 vertically hold the foot channels
60 to the cross runners 14b while the insertion of the ceiling tile
91 maintaining the foot portions 63 against the vertical webs
16b.
The additional supporting means 70 of the third alternative
preferred embodiment includes the provision of one or more
longitudinal channel members 73 along the sides of the duct board
member 40. The members 73 each have an offset tongue 74 in one end
and a pair of notches 75 in the sides thereof as well as a hole 76
in the web thereof adjacent the other end. The tongue 74 is sized
to be inserted between the sides of the longitudinal channel member
73 for a purpose which will appear later. The notches 75 are for
receiving a soffit wire 18 therein which is clamped therein by
clamping or anchoring means 80. The clamping or anchoring means 80
shown includes a smaller clamping member 86 with a hole 87 therein
for receiving a sheet metal screw 88 therethrough. The screw 88 is
sized to be threaded into the hole 76 in the web of the
longitudinal channel member 73 to draw the clamping member 86 over
the soffit wire 18 and toward the web, thereon, bending the soffit
wire 18 inwardly as seen in FIGS. 9 and 10.
If the ductboard channel members 40 are to be combined, then the
tongue 74 of one member 73 will extend into the next member 73
behind the soffit wire 18 after which the clamping member 86 will
bend the wire 18 thereagainst to interlock the longitudinal channel
members 73 for supporting the ductboard section 55. If so desired,
the transverse members 71 could also be provided, though there
would probably be no need for hooks 81 as the clamping members 84
will perform the function of the anchors 81.
The third alternative preferred embodiment is constructed by
cutting a ductboard section 55 from a supply of ductboard, cutting
the longitudinal notches 58 in the ductboard sections 55, and
folding the section 55 into a an inverted U-shape. The section 55
will now probably have its lower edges 59 inserted into the channel
portions 61 of the foot channels 60 to be secured therein by the
teeth 62. The longitudinal and transverse members 73 and 71 are
secured to the sides and the web of the ductboard section 55 if
they are desired or needed.
The section 50 so folded and assembled is inserted through the
framework 13 into the attic space thereabove, and lowered until the
foot channels 60 are located on and between the cross runners 14b.
The transverse members 71 are located between soffit wires 18. An
adjacent tongue 74 is inserted into the longitudinal channel member
73 and the soffit wire 18 is located in the notches 75 ready for
the clamping member 86 to clamp the wire 18 against the tongue 74.
The screw 88 are tightened to move the clamping member 86 and
thereby complete the mounting of the third alternative preferred
embodiment of the channel member or troffer 40 in the framework 13.
The ceiling tiles 91 will be installed as before.
Thus, the air troffer of inverted channel members 40 and the
blocking means 90, according to this invention, can be supported by
the suspended ceiling framework 13 to permit the air troffer to
have as large a cross-sectional area as needed and yet deliver the
conditioned air to the air control means 20.
While the inverted channel member 40 and blocking means 90 have
been heretofore described as an individual unit, each channel
member 40 must be combined with other aligned channel members 40 to
provide an effectively continuous troffer array 95 to form an air
distribution system 10 for a room 11.
As shown in FIG. 1, it is contemplated that the channel members 40
will be combined in effectively continuous troffer arrays or rows
95 which will then be provided with a centrally located wall 96 to
divide each array or row 95 into two halves. A cross duct 97 will
be located between two adjacent halves and will be fed conditioned
air from a vertical supply duct 98. The conditioned air passes down
the supply duct 98 into the cross duct 97 where the air is carried
to the troffer arrays or rows 95. At the juncture of the troffer
array or row 95 with the cross duct 97, a splitter air vane unit
99, as shown in FIG. 4, will divide the conditioned air and direct
its flow in opposite directions along the troffer array or row 95.
The conditioned air is carried by the troffer array or row 95 along
the air diffuser assembly 21 to be diffused thereby into the room
11.
As seen by comparing FIGS. 2 and 3, there are illustratively shown
two different embodiments of troffer arrays or row 95. FIG. 2 shows
a preferred troffer array or row 95 which is composed of individual
inverted channel members 40 having sides 42 of generally uniform
height. In the preferred embodiment of the troffer array or row 95,
as conditioned air passes through the air diffuser assembly 21 into
the room 11 below, the velocity pressure in the troffer row 65 will
decrease. Since the cross-sectional area of the troffer row 95
remains the same, velocity of the conditioned air flowing in the
troffer row 95 will decrease. The velocity of the conditioned air
in the troffer row 95 will eventually reach zero at the wall 96 and
the velocity of the conditioned air being diffused through the
diffuser 21 will likewise drop. Normally such a drop in the
velocity of the diffused air towards the ends of the troffer rows
95 will not be objectionable.
However, for those circumstances where such a drop in the velocity
of the air being diffused might be objectionable, the alternative
preferred embodiment of the troffer array or row 95 is provided. As
seen in FIG. 3, the alternative preferred embodiment of the troffer
array or row 95 has groups of inverted channel members 40
(typically three to a group) whose sides 42 decrease in height in
both directions from the channel member 40 supplied by duct 98. The
decreasing height of the sides 42 decrease the cross-sectional area
of successive inverted channel members 40 in both directions, to
compensate for the loss of conditioned air through the air diffuser
assemblies 21 and maintain a generally constant air flow velocity
along the troffer array or row 95. The constant air flow velocity
provides a generally constant velocity to the conditioned air being
diffused into the room 11 along the length of the troffer array or
row 95.
Thus the suspended ceiling framework supported troffer air
distribution system 10, according to this invention, provides an
air troffer system which has sufficient cross section area to
deliver air across the width of a room. Additionally, the system
10, according to this invention is easily, simply and inexpensively
mounted to the framework of a suspended ceiling over an air control
means carried by the framework to conduct conditioned air thereto
for diffusion throughout the room below.
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