US2926237A - Ceiling lighting system - Google Patents

Description

Feb. '23, 1960 s. E. SORENSON CEILING LIGHTING SYSTEM Filed Nov. 12; 1957 2 Sheets-Sheet 1 INVENTOR.

Stanley E.$orenson Attorneys Feb. 23, 1960 S. E SORENSON CEILING LIGHTING SYSTEM 2 Sheets-Sheet 2 Filed NOV. 12, 1957 INVENTOR. Stanley E. Sorenson BY 2 Attorneys United States Patent CEILING LIGHTIN SYSTEM .channel headers, normally termed lathers channels in the art. Cross-runners are clipped beneath these channels and either interfit by horizontal bottom flanges with kerfs 1n the tiles or, in the case of an accessible system,

- may carry removable hangers which interiit with the tile.

The length of the tiles determines the modular spacing 'of the runners and the lathers channels are desirably spaced at regular intervals, the module of which is an even multiple of the runner module. Normally therefore, the'runners are spaced either 1 or 2 feet apart,

and the channels preferably are given a 4 foot modular spacing, the latter normally being considered very adequate to meet ceiling and lighting'fixture loading requirements.

When the lighting is to be performed by recessed troifers, the troffer is usually made of such a size that it can be interchanged with one or more-ceiling tiles, a 2 x 4 foot fixture being common. The troifers are frequently run parallel to the channel courses in which case an extra course or two is added along'the sides of the troifer to carry laterally extending yokes to which the troifer is connected. Such an arrangement has the objection that it frequently interrupts the courses of the runners. i i v In some installations the trotfers extend at right angles to the channel courses and are provided with end books which fit over a pair of the channels to supportthe trotfer. Since, in such an installation the troffers are parallel to the runners, cutting of the latter is 'kept to a minimum. However, with troffers heretofore known, it has not been possible, because of resulting interference by the channels, to place several of the troffers in end-to-end' contact in a continuous uninter courses of the-runners to be interrupted, therebynecessh tating objectionable frequent cutting of the runners.

My invention aims to provide an improved troffer of simple and economical construction which permits a plurality of'the troffers to be placed in a continuous run supported by theflathe'rs channels in a concealed mechanical ceiling suspension system without interfering witht normal layout of the channels and cross-runners of the system. The invention further aims to provide such a troifer which can be originally'quickly installed and thereafter easily shifted to another ceiling location should change in the lighting layout be desired, as for a new building tenant. j

With yet additional objects and advantages in view which, with the foregoing, will appear and be understood in the course of the following description and claims, the invention consists in the novel construction and in the adaptation and combination of parts hereinafter described and claimed.

In the accompanying drawings: Figure 1 is a fragmentary perspective view portraying a suspended ceiling including alcourse of trofi'ers made in accordance with preferred teachings of the present invention, the said ceiling being viewed from above.

Fig. 2 is a fragmentary transverse verticalsectional view drawn to an enlarged scale on line 2-2of Fig. 1. Fig. 3 is a fragmentary transverse vertical" sectional view drawn to an enlarged scale and detailing the j catch structure by which the root end of a swingably mounted access door for the troifer'is. removably attached to the hood portion of the trolfer. Fig 4 is a fragmentary longitudinal vertical sectional view drawn to. the scale of Fig. 2 on line 4-4 thereof, this view including outer end portions of a course of in-line troffers but omitting any showing of abutting inner ends thereof.

Figs. 5 and 6 are fragmentary perspective views employing a scale substantially the same as that of Fig. 3 and respectively detailing the free-end connection and the root-end connection between the access door and the 'troffer' hood. More particularly, the vantage point of Fig. 5 is. represented by the line 5-5 of Fig. 2 and the structure detailed in exploded relation'in Fig. 6

, corresponds to that detailed in Fig.3.

Fig. 7 is a fragmentary side elevational view portraying abutting inner ends of two adjoining trolfers. For purposes of example, in Fig. 1 I have illustrated several of my trotfers 10 mounted in continuous end-toend relation in an acoustical tile ceiling having a concealed suspension system of' a so-called accessible type, that is.to say, one by which the tiles 11 are individually removable. In this particular system as in most concealed systems, the runners 12 are held by generally U- shaped clips 13 at cross-angles to the lathers channels 14 which in turn are suspended as by wires 15 from the overhead structure. The channels are normally spaced at 4 foot intervals and the runners have a 2 foot module. It will be noted that each runner 12 is generally channelshaped and that its upper flange is stepped to provide upper and lower steps Mae-46b. The upper step is grippedby feet 13a formed at the bottom of the legs of the clips 13 while the lower step directly, overlies the lower flange 17 of the runner. Elongated hangers 18 having an angular cross-section throughout most of their length extend between the runners. At one of its ends each of these hangers has its horizontal flange prolonged and upwardly offset to provide a hanging 'lip 19 for rest- I ing on the lower step 16b"of'a runner while the other end of the hanger rests on thelower. flange. of the next adjacent runner. The-tiles 11 are kerfed' and backcut to interfit with the hangers and the'resulting kerfs 11a are sufliciently wider-vertically spealting than vthe thickness of the lower flanges 17 of the runners to permit the end of each tilecorre'sponding to the-hanging lip end of the related hangers to be tilted upwardly with the hangers about the other end of the latter'as apivot such that the tile and hangers can thereupon be freed is shown for illustrative purposes only and that concealed systemswith othevshapes of runners, inverted-Tor otherwise can also accommodate my troffer in the same manner. Continuing to a description of the trotfer, such is of sheet metal construction and has an inverted trough Lat.the :top sforrningqa-zwireway 21.-collectively::witl1 a Twrefiector 22...-;The latter is screw-mounted at itsaends to opposed flanges 23 formed at the top of a ,pair of end :plates 24.:, -.B.etween. the flanges 23.;and the end-plates .proper,-there.is. provided respective .steps .ZSreach of which vhas cutouts 26Joining withavertica-Lcutouts 27 in=the rest of: the corresp.'onding end-plate to .receive socket .holders 28,: These are generally T-shaped and may be of the type shown in US. Patent No. .2,262,09l.

The arms of each-socketsholder. rest-on the. portions 0f. the step ateithehsidlof its cutout 26 rand-project inwardly of the..trolfergwith;- .respect toithedepending .socketed portionof. the .holderto receive. alocking screw 30. It'will benoted that theendlplates 2,4 have-inwardly .bentrend tabs 31 hayingascrewconnection with the ends of the trough 20 and; are formed at a bottom-support... edgev 32 with inwardly .directed. troffer support fianges 33. The latter have a width at least half that of the-channels and desirably terminate by a downturned locking lip 34... At. the: same level as the vflanges 33,

the trough 20 formed .Withoutturned longitudinal .tlanges 35 for .carrying.adjustableskirts 36; Each of these skirtshas three steps 37 to 39, theupper of which receivesheight adjusting screws (which are threaded intoncaptive rnuts.4l0a.fitted over the trough flanges 35.

Any gap between'these flanges and the top, skirt steps 24; The lower steps 39 serve as trim flanges and are matched at the endsrof-th'etrofler by trim flanges 44 provided bytremovable. trim members 45 which-are. cut at their ends to mate .with the contour of theskirts and have end tabs 46 which are screwed to the lower risers 47 of the skirts.

The middle skirt steps 38 serve as the jambs for a removable door frame 48 which has concealed separable T-hinges 50 along one of its longitudinal side bars 51.

These hinges projectrinto suitable T-slots 52 formed in the risers 47.1 The construction of the doors is of no particular moment to the present .invention'other than thattheir overall length should correspond tothe centerto-center modulebetwee'n the lathers channels '14 so that when the troifers are in "end torend relation as shown in Fig. 7, the doorsuwill match the length of the trim flanges 39 of the skirts 36 and together therewith hide the overhead structure; As seen in the drawings, the longitudinal side rails'sl. interfit with removable end pieces 54 and throughout most of their length are bent inwardly along a shoulder 51a.'- This shoulder cooperserves to retain the longitudinal side edge portions of a lens panel 55 or, other suitable diffuser.

The riser portion 512: adjoining the shoulder 51a along one side of the door is the anchor for the root ends of the T-hinges 50 an'dalong the other side of the door it "hassecured thereto the mounting ;bracket 56 for one or more pivoted-'trigger-latches 57." The trigger 58 or each latch projects downwardly through slots 64) in the shoulder'51a andbottdrn lip 51b to beaccessible and" the below. the top of the. corresponding lather-Ts; channels 14 and tcollectivelyrwith the. end vplate flanges 3.4. restrain the troffer against, endwise movement relativeto .suchchannels.

It will be apparent that one of my trolfers can be readily installed aftenfirst removing its door and skirts 36 by loosening the screws 40, then tilting the remainder of the troffer endwise lifting it up between the pair of channels 14 on which it is to be carried, and then lowering it ontoithechannels. :The skirts can then be raised up and screwed into place. When a lighting run longer than the-single 'trofferis desired, additional trofiers are similarly" installed 'end-to-end with their 'wiring interconnected in the resulting continuous wireway 21. The enclsof theilatter may be closed by cover plates '64 formed with suitable punch-outs for introducing the wiring to the wirewayp Similarly, the trofiers at the ends of the run are equipped with the lateral trim flanges 44 which together with the trim flanges 39 of the skirts give a continuoustrimtbeneath the tiles 1'1- and which-pm'ay be a .used togive .partial support to-the; tiles bordering the v,If it is desired 'to'move' one or more of theitroffers,

..it is. only necessary to remove the tiles at the relocation site, shift the trotfers thereto, and install the removed ...,.tiles in'the. former site ofthe trofifers.

The: advantages of the invention,.it is thought,,..will have been clearly. understood from the foregoing detailed ,description of the ..-illustrated 1 preferred embodiments. Minor .changes willsuggest.themselvestand may be resortedtowithout departing from the spirit of the inven- :tion, whereforeit is myintention that no limitations be implied andthat thehereto .annexedclaims be given a scope. fully commensurate.with;the broadest interpretation to=whichthc temployedlanguage admits.

What Lclaim, is:

, 1. hr a recessed lighting .tmtfer for resting directly on a pair of suspended parallel horizontal'headers which are zspaced apart",tcentereto-center a given module, an invertedttrough like frame'assemblyhaving its ends formed with trofier support edges spaced apart thegiven module for resting on said headers and defining a support level,

....-longitudinal. skirts hanging from the sides of said. frame assembly to a level below said support level so as to extend below the headers, said skirts being shorter than :saidrmodule. through at least an'uppermost portion of a their heightso .as 'to depend between the headers, a .door fr ame movablythung onsaid skirts and corresponding in length Vtorsaidr. module,- the end portions of said door v 'frame being spaced below said support level so as to lie beneath the headers, and a pair of opposed light'socket members mounted in :said frame assembly at opposite .a-endsthereof above said support levelwith theirsockets -:;;facing-inwardly and their backs spaced apart said module, arsaidsskirts.ubeingadetachable from said frame assembly whereb.y said frame assembly can be longitudinally tilted 55.- tween a pair of, said-headers, whercafter itcan be ates with a bottom lip 51b to form a channel which while t'he-skirts are: detached and raised. while tilted belowered horizontally to position its ends on said headers and theskirts thereupon.- raised bringing their'said uppermost portions between saidheaders for attachment to the frame .assembly.

2. In a recessedlighting,trofier for resting'directly with trofier support edges spaced apart the given module for resting onsaidheaders and defining. a support-level,

.glongitudinal..skirts hanging from the sides of saidframe zassemblytof a levelbelow saidsupportlevel, said skirts eachfhayinga length at the bottom. correspondingto said.

module andbeinginwardlysotfset at both of itS -.6nds

to;.;form tagshorter .uppermost longitudinal :'skirt portion for ,extendingbetween thesheaders to make. operative association with said frame assembly, a door .frame movably,hung onrsaid skirts and corresponding ,in length to tsaid module theend portions of .said door 1 frame :being spaced below said support level so as to lie beneath the headers, and a pair of opposed light socket members mounted in said frame assembly at opposite ends thereof above said support level with their sockets facing inwardly and their backs spaced apart said module, said skirts being detachable from said frame assembly whereby said frame assembly can be longitudinally tilted while the skirts are detached and raised while tilted between a pair of said headers, whereafter it can be lowered horizontally to position its ends on said headers and the skirts thereupon raised bringing their said uppermost portions between said headers for attachment to the frame assembly.

3. The trolfer of claim 2, in which the lower edge portions of said skirts are bent outwardly to provide longitudinal trim flanges.

4. The troifer of claim 3 in which lateral trim flanges are detachably mounted on the ends of said skirts to extend outwardly in coplanar relation with said longitudinal trim flanges.

5. The troffer of claim 2 in which end pieces interconnect the ends of said skirts below said offsets thereof.

6. In combination, a concealed ceiling suspension system having suspended horizontal headers arranged in regularly spaced parallel courses, runners held against the underside of said headers in rows extending at right angles to the header courses and spaced apart a given module, the spacing interval of said header courses being an integer multiple of said module; ceiling tiles carried by said runners and forming a ceiling surface therebeneath concealing the runners from below such surface; and a continuous column of recessed lighting troffers located between and free of two of the rows of runners and straddling the courses of headers in the path of the column, each of said troffers being of a length above said headers corresponding to the center-to-center distance between the header courses and being supported directly by and solely by headers at each of its ends, said troffers in the column collectively presenting a wireway at the top thereof and a trim flange which surrounds the bottom of the column and has its upper surface at said ceiling surface and extending beneath said two rows of runners at the sides of the column, and troifer doors carried by the troifers and filling in the space surrounded by said trim flange.

7. The structure of claim 6 in which removable cover plates are mounted above the level of the headers on the outer ends of the troffers located at the ends of said column and are arranged to close the ends of said wireway. 7

8. In combination, a given layout module, a concealed ceiling suspension system having suspended horizontal headers arranged in parallel courses spaced apart center-to-center an integer multiple of said module and having runners for carrying ceiling tile clipped against the underside of said headers in a pair of parallel rows extending at right angles to the header courses and spaced apart center-to-center an integer multiple of said module, a continuous column of recessed lighting troffers located between and free of said runner rows and straddling at least one course of headers, each of said trotfers being of a length above the level of said headers corre sponding to the center-to-center spacing of the header courses and being supported directly by and solely by respective headers at each of its ends, said troffers being in end-to-end abutment above the header level and being electrically interconnected at their abutting end portions above such level, each of said troifers having detachable longitudinal side skirts depending between the respective headers and jutting endwise beneath such headers into end-to-end abutment, said skirts presenting trim flanges at the bottom so that the troffers collectively present a continuous trim flange along each of their bottom longitudinal side edges, said trim flanges being spaced below the level of said runners, removable end pieces mounted below the level of the headers on the outer ends of the troffers located at the ends of said column and presenting trim flanges mating with the aforesaid longitudinal trim flanges to enclose a rectangular area having its length and width each a respective integer multiple of said module, and door means filling said rectangular area and movably mounted on some of said skirts.

9. In combination, a concealed ceiling suspension system having suspended horizontal headers arranged in regularly spaced parallel courses, runners held against the underside of said headers in rows extending at right angles to the header courses and spaced apart a given module, the spacing interval of said header courses being an integer multiple of said module; ceiling tiles carried by said runners and forming a ceiling surface therebeneath concealing the runners from below such surface; and a continuous column of recessed lighting trolfer assemblies located between and free of two of the rows of runners and having their ends straddling top and bottom the courses of headers in the path of the column, each of said troffer assemblies having longitudinal end supports resting directly on respective headers at each end of the trofier assembly and having lateral skirts with terminal end portions jutting beneath such headers, at least one of said end supports of each troffer assembly being movable relative to said skirts thereof for installation of the troifer assemblies, said column presenting an upper straight wireway. and a trim flange which is carried at the bottom of said skirts and surrounds the column, said trim flange having its upper surface at said ceiling surface and extending beneath said two rows of runners at the sides of the column, and troffer doors carried by said skirts of the troffer assemblies and filling in the space surrounded by said trim flange.

References Cited in the file of this patent UNITED STATES PATENTS 2,616,533 Gannett et al. Nov. 4, 1952 2,625,646 Gobel Jan. 13, 1953 2,694,139 Zurawski Nov. 9, 1954 2,713,631 Spinetta July 19, 1955

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