US3506822A - Universal air handling troffer frame - Google Patents

Description

April 14, 1970 G. E. MULV EY ETAL UNIVERSAL AiR HANDLiNG TROFFER FRAME 2 Sheets-Sheet 1 Filed Dec. 4, 1967 FIG 4 FIG 5 6 INVENTORS FIG GERARD E. MULVEY GEORGE April 14, 1970 G. E. Mum/Ev T AL 3, 2

UNIVERSAL AIR HANDLING TROFFEB FRAME 2 Sheets-Sheet 2 1 Filed Dec. 4. 1967 INVENTORS EE 1 G United States Patent Office 3,506,822 Patented Apr. 14, 1970 US. Cl. 240-9 6 Claims ABSTRACT OF THE DISCLOSURE A supporting frame for use with light trofiers of the kind employing fluorescent lamps. In order to support the support the light troffers in position in the ceiling, the frames are constructed separately and are of a readily variable design to accommodate changes in length, without affecting the light trofi'ers. Also provided is a method for custom designing of lighting installations at very low cost without altering the light troffers, and as such is adaptable for use with or without air handling facilities without revealing any apparent alteration to the naked eye. The troffer frames are preferably formed of extruded material such as aluminum and provided with concealed attachment flanges to which the sheet metal trofler boxes can be attached.

This invention relates to a frame for light troffers having air handling facilities.

Current building systems employing false ceilings usually incorporate fluorescent lighting systems which are recessed flush with the false ceiling. In order to reduce the number of openings in the ceiling, it is a common practice to incorporate air handling slots alongside some or all of the light troffers to accommodate the air conditioning needs of the space, some of such slots being the air delivery slots and others being the return air slots. In order to facilitate installation of such light trofiers, and their connection to the air delivery and return ducts, the light trotfers and air handling delivery and return opening means are usually formed in a single integral structure fitting within an opening of predetermined size in the false ceiling. Various forms of such air handling light troffer assemblies have been manufactured in the past, but have suffered from a variety of defects. Thus, for example, it is commonplace that air handling openings in ceilings and the like for air conditioning lead to an accumulation of dirt around the edges of the opening, and also to a discolouration of the paint, or other surface material. One way in which this can be overcome is to employ bigger and bigger openings leading to reduced air flow velocities but such larger openings tend to be unsightly. In addition, the use of over sized slots around the lens of the lighting fixture itself is unacceptable for other reasons. In general, the design of a false ceiling is such that the size of the opening in the ceiling is determined by the design of the ceiling and cannot be enlarged to accommodate greater slots. Thus if it is attempted to increase the size of the slots, it can generally speaking only be achieved at the expense of a reduction in the size of the lens of the lighting fixture. This leads to an increase in brightness of the lens which is itself the subject of restrictions under accepted building practices. Thus, it will be apparent that designs of air handling openings in the past have generally been directed to obtaining the smallest possible opening with a resultant high rate of accumulation of dirt and discolouration.

A further disadvantage of prior light troffer designs is that the use of slotted air handling openings in some of the light troffers in an area lead to a non-uniform appearance with some of the troffers incorporating slotted openings and others being blank. In addition, the slots themselves are unsightly since they constitute black openings in the ceiling without contributing to the aesthetic appearance of the trotfers.

A still further disadvantage of prior art troffers, lay in the fact that in general, they were manufactured wholly or substantially completely of sheet metal and did not readily lend themselves to minor adjustments in length. In addition, they could not ingeneral span a distance greater than about four feet, the length of the normal mercury tube, which restricted their use in various ways. Thus, when using four foot troffers in a ceiling designed with four foot modules or modules of four feet by eight feet, the troffers could span the distance between two of the ceiling supporting Ts without difficulty, and when placed end to end so as to achieve the most efficient light distribution pattern they would be spaced apart only by the width of such T. However, it was generally speaking not possible to use such standard four foot troifers with ceiling which did not incorporate a four foot module. Thus for example, when using a ceiling designed on a five foot module, it was formerly necessary to provide some other means of supporting the troffers, other than simply resting them on the ceiling T. In addition to providing some other form of supporting means, it was also necessary to fill the spaces at one or other end of the trolfers thereby breaking up the pattern of the ceiling.

In addition, the dimensions of a ceiling are generally speaking subject to fairly broad tolerances due to variations in the exact dimensions of the outside walls of the building, particularly in the case of poured concrete construction. As a result, it frequently occurred that the troifer at one or other end of a row of troffers required shortening to accommodate such tolerances and the sheet metal construction of prior art trolfers caused great difficulty.

When arranging partitions for a space illuminated by rows of light trotfers, it is necessary to arrange that the partitions do not overlap the lenses of the troffers. Thus some spacing between troffers arranged end to end becomes necessary, making the use of a five foot ceiling module, coupled with light troffers somewhat shorter than five feet, and accommodating four foot mercury tubes, as a highly desirable solution. However, due to the problems mentioned above in connection with supporting the standard four foot troflers in a five foot ceiling, a satisfactory solution to this problem has never been achieved at an economical price.

The invention therefore seeks to provide as a principal objective, a universal frame work upon which the light troffer can be mounted which is cheap and simple to construct, which may incorporate air handling slots if desired with only minor structural alterations and without in any way alterating the appearance, and in which such slots are to all intents and purposes invisible, which frame may readily be arranged to span varying spaces between ceiling TS and which may readily be adjusted or modified as to length without the necessity for alterating the light troffer itself.

More particularly, it is an objective of the present invention to provide a light trolfer frame of inverted channel shaped construction adapted to incorporate air handling slots in one side wall of such channel, the channel being inaccessible to light from the troffers thereby concealing the air handling slots from view.

More particularly, it is an objective of the present invention to provide a frame for light troflers which is formed from continuous lengths of channel shaped stock, cut into lengths to span the spacing desired and having upwardly directed attachment means for attachment of a light troffer thereto.

More particularly, it is an objective of the present invention to provide a frame for light troffers which itself incorporates supporting means for engagement with the adjacent ceiling Ts.

More particularly, it is an objective of the present invention to provide a frame for light trolfers incorporating end panels at each end of the troffer whereby the troffers themselves can be made somewhat shorter than the spacing between the Ts, the end panels on the troifer frame filling the space threbetween thereby rendering it possible to erect partitions passing between any two such light trolfers arranged end to end without the necessity of modifying the light troffers or replacing them with shorter troifers.

The foregoing and other objectives of the invention will become apparent from the following description of a preferred embodiment of the invention which is given here by way of example only with reference to the various views and diagrams in which like reference devices refer to like parts thereof throughout the various views and diagrams and in which;

FIGURE 1 is a perspective illustration of a troffer frame according to the invention showing the light troffer and mercury tubes in phantom form supported in location in a ceiling partially cut away to reveal the construction thereof;

FIGURE 2 is a section along the line 2-2 of FIG- URE 1 showing one side of the frame and light troifer coupled to an air handling duct;

FIGURE 3 is a greatly enlarged perspective illustration of the corner detail of a frame according to the invention;

FIGURE 4 is an enlarged secion of the trolfer frame according to the invention along the line 4-4 of FIG- URE 1 according to one embodiment thereof;

FIGURE 5 is a section corresponding to the section 44, showing another embodiment of the troffer frame suitable for use with alternative forms of ceiling construction; and

FIGURE 6 is a section along the line 66 of FIGURE 1 showing the details of the end construction of the troffer frame.

From FIGURES 1 and 2 it will be noted that these illustrations show a conventional form of ceiling construction comprising a criss cross network of supporting Ts 10 supported at intervals by wires 11, and providing support for ceiling tiles 12. In this embodiment, the basic ceiling module is five feet square, each module being filled by two tiles 12, five feet long by eighteen inches wide, and between them a trolfer frame, indicated as 20, five feet long by two feet wide, although, obviously other forms of ceiling modules may be accommodated according to the practice of the present invention without departing from the scope of the invention.

The trolfer frame according to the invention comprises side members indicated as 20, end members 21 and, where desirable, there may be provided one or more intermediate members 22 running one way or the other between either end members 21 or side members 20, depending upon the desired dimensions of the frame, and the light characteristics of the particular troffer employed. A trofier indicated in this example in phantom and shown by the reference T is attached to the frame side and end members 20 and 21, and is provided with conventional fluorescent lamps and lenses L. In FIGURE 2 an air duct D is shown merely by way of example, being attached to frame side member 20 to be understood that the duct D may be either the air delivery or the air return duct, there being no material difference for the purposes of the invention apart from the fact that the air delivery ducts would normally be connected with light fixtures around the outside wall of the building? and the air return ducts would normally be connected with light fixtures grouped around the central portion of the space. The side member 20 of the trolfer frame will be seen to comprise an inverted channel shaped section having inner and outer channel side walls 23 and 24 and a channel upper wall 25, together defining three sides of a rectangle, in this preferred embodiment the lowermost portion of which is open to define a continuous open mouth indicated at 26. In order to detach frame side member 20 to a light trotfer such as T, an attachment flange 27 is provided along the upper sides of channel upper wall 25 thereby permitting self-tapping screws such as 28 to be fastened therethrough at intervals, without interfering with the appearance of channel upper wall 25.

In the embodiment of FIGURES 1, 2, 3 and 4, channel side member 20 designed so as to be self supporting on ceiling Ts 10. For this purpose, a horizontal rib member 29 is formed along the outer surface of outer channel wall 24 being preferably spaced above the lowermost limit thereof by a distance equal to the thickness of ceiling T 10, whereby to achieve a uniform flat appearance as shown.

Frame end members 21 are similarly provided with inner and outer channel walls 30 and 31 and channel upper wall member 32 defining a rectangular configuration identical with that of channel side member 20 and having an open mouth 33, whereby to provide an identical uniform appearance around all four sides of the lighting fixture. A flange member 34 is arranged along the upper surface of channel upper wall 32 but of reduced height as compared with flange 27, since there is generally speaking no need to attach the light trofler T at these points, the main purpose of flange 34 being merely to control the location of lens L, although obviously if additional attachment is felt to be necessary, depending upon the design of the particular light troffer, flange 34 could be increased in height to permit its use for attachment as in the case of flange 27. In this preferred embodiment, it will be understood that the length of frame side members 20 is preferably somewhat less than the length between ceiling Ts 10, whereby to provide spacing between the ends of adjacent light ing fixtures to permit the erection of oflice partitions at any desired location in the space. In order to fill the space between frame end members 21 and the adjacent ceiling T5 10, extension members 35 are formed integrally with the lowermost edge of outer channel walls 31 of frame end member 21, having an under surface which is designed to lie in the same plane as the under surface of ceiling Ts 10 and thereby present a uniform flat appearance. Horizontal supporting ribs 36 are formed on the outer edges of extension members 35, and being in a plane offset with relation to the plane of extension members 35 whereby to lie on the horizontal portion of ceiling Ts 10 and provide additional support. Naturally, the width of extension members 35 will depend to some extent upon the particular design of the ceiling module, and also upon the anticipated maximum width of partitions which will be erected in the space at some future time. For example, but without limitation, in the presently preferred embodiment, the ceiling Ts 10 may be one and a half inches wide, and the extension members 35 may be approximately two inches or a little more in width, thereby giving a total of between five and a half and six inches available for erection of partitions between the ends of adjacent lighting fixtures, without in any way impairing either the efficiency or the aesthetic appearance of the fixtures. It will be understood that the troffer frames according to the invention may be employed both with and without air handling facilities, without in any way altering the appearance of the lighting fixture to the naked eye. Thus when it is desired to connect air handling facilities, all that is required is to for-m a series of air handling slots 37 in the outer channel walls 24 of frame side members 20, and air handling duct of standard design such as the duct being shown in FIG- URE 2, may be connected for either delivery or return air.

The construction of the corners of the trolfer frame according to the invention are shown in FIGURE 3. It will be noted that frame side member 20 and frame end member 21 are each cut through their respective inner and outer side walls 23 and 24 and inner side walls 30 and 31 and upper walls 25 and 32 at angles of 45, and welded together as at 38 around only their outer and upper surfaces whereby such weld 38 is completely concealed from the naked eye. While the particular construction of a trolfer frame according to the invention may be subject to variation in design either with a view to altering the appearance, or due to the need to provide greater support for lenses L or due to variations in the ceiling module, in the presently preferred embodiment it is found desirable to provide an intermediate frame member 22 running parallel to side members 20 and attached at each end to end members 21 by similar welding techniques. Intermediate member 20 is of identical construction to side members 20 but without the provision of supporting rib 29 and obviously, no air handling slots 37 are provided. Obviously, although not illustrated, it would be possible to add a further intermediate member 22 running the opposite way at right angle to intermediate member 22 as shown, if a lighting fixture of greater size requiring further support for lenses L were required.

According to a further embodiment of the invention, as shown in FIGURE 5, where other means of support for the lighting fixture are provided in the building design, and where some other form of ceiling support other than celing T are employed, for example, side member 20 may be designed as shown in FIGURE 5, being substantially identical to the side members 20 shown in FIGURE 4, but without the use of supporting rib 29. Alternatively, a junction flange such as is shown in phantom form in FIGURE 5 and illustrated as reference 39 may be provided at an angle, if for example, it is desired to employ a plastered ceiling construction.

It is to be understood that by the use of troffer frames according to the invention, a rigid integral frame work is provided of material which is particularly suited for economical production in any length required, preferably employing aluminum as the material, and forming I it into the desired shape by means of extrusion, although other materials and methods of construction are obviously suitable. The use of a deep rectangular channel section provides a rigid girder like member providing great resistance to deflection under the weight of the associated light trotfer, while also permitting the incorporation of air handling slots in a highly advantageous manner. Thus, the deep channel section may preferably be painted or coated with a dark matt surface, and when placed alongside the principal source of direct lighting namely the lens L, will in fact appear to be totally black to the naked eye and it will not be possible to see how deep such a channel may be nor what may be concealed within it. The air handling slots formed within the outer channel wall in such a channel will generally speaking be the point around which the discolouration and dirt will accumulate, since they are the points of greatest restriction, the channels themselves defining considerably greater volume available for air flow. Such dirt and discolouration will generally speaking be completely concealed or hidden thus avoiding staining of the ceiling and requirement for frequent and costly maintenance. In the case of buildings having ceilings of varying dimensions, minor adjustments may be made to the length of the trotfer adjacent to one end of a row of trotfers by simply cutting off a certain amount of an extension member on one of the frame end members. Alternatively, if greater adjustment is required, it is possible at very little extra cost to reduce the overall length of the frame side members without in any way affecting the construction of the light trotfers themselves, the ends of which may simply be permitted to overhang the frame end members.

It is to be understood that according to the invention, the troffer frame may be employed with various different kinds of ceiling construction other than that illustrated. For example, the ceiling tiles may be supported by other means such as H section members fitting within the grooves in the tiles in known manner thereby providing concealed support. Alternatively, the ceiling may be of plaster construction, in which case the light troffer and troffer frames attached thereto will be supported by some other means such as wires or steel rods connected to the floor above whereby to suspend the light troffers at the desired level in the ceiling. Other means such as yoke or braces extending over the light troffers and engaging the ceiling supporting system in well known manner are also within the scope of the invention.

It will also be appreciated that while the invention has been described in connection with light troffers employing recessed lenses, that the location of the lens in relation to the construction of the trotfer frame is a matter of choice, and obviously, the lens may be suspended flush with or even below the trotfer frame without departing from the scope of the invention. Furthermore, when it is desired to construct a frame in which the frame end members do not incorporate extension members, at one or other ends, then the frame end member section may merely be replaced by a section of the frame side members, without defecting any substantial alteration in the appearance of the trotfer frame to the naked eye. This may be particularly advantageous when it is desired to arrange troffer frames of reduced lengths close to a Wall.

What we claim is:

1. An integral air handling supporting frame for attachment to a light trotfer having an open lower side to form therewith a lighting fixture adapted to be supported in a ceiling, said frame supporting the lens of said lighting fixture independently thereof and providing the visible portion of said lighting fixture, and comprising;

a pair of frame side members of equal length;

a pair of frame end members of equal length;

means joining said side members and end members at corners at right angles to one another forming the same into an integral rectangular frame, said side members and said end members defining in section an identical recessed upwardly extending channel having parallel inner and outer side walls and a top wall normal to said side walls, said channel being continuous around said side and end members when the same are associated together to form a said frame and forming a light trap with respect to light radiating from a light troffer atached to said frame;

lens supporting means defined by said side and end members lying in a common plane for supporting a lens of a said lighting fixture independently of said fixture;

concealed attachment means formed on the upper side of said side members at least for attachment around said open side of said light troffer; and

air handling slot means formed in said frame side members.

2. A support frame as claimed in claim 1 including an attachment flange extending continuously along the upwardly directed portions of said side members, and attachment holes formed therethrough at intervals for fastening to said light trofr'er.

3. A support frame as claimed in claim 1 including support rib means formed along said outer side walls of said frame side members at least for interengagement by and with portions of the ceiling surrounding said lighting fixture.

4. A support frame as claimed in claim 1 including extension means formed integrally with said frame end members extending outwardly endwise therefrom.

5. A support frame as claimed in claim 1 wherein said top Walls of said side and end members lie in a common plane and constitute said lens supporting means and support and locate said lens independently of said light troffer in a plane spaced above the lower edges of said side Walls of said side and end members, recessing said lens within said frame members and maximizing the open area thereof for passage of light therethrough.

6. A support frame as claimed in claim 1 wherein said lighting fixture incorporates two lenses and including a further intermediate frame member extending between said frame end members midway therealong and defining in section the same upwardly extending channel as said frame side and end members, whereby to provide intermediate lens support means permitting said lenses to be supported side by side. 7

References Cited UNITED STATES PATENTS 2,846,569 8/ 1958 Frizzell et a1. 3,103,868 9/1963 Kodaras. 3,154,001 10/ 1964 Zurawski. 3,190,208 6/1965 Styne et 211. 3,193,001 7/ 1965 Meckler. 3,246,137 4/1966 Zagel. 3,383,811 5/1968 Ades 52128 FOREIGN PATENTS 705,764 4/ 1965 Canada.

NORTON ANSHER, Primary Examiner R. L. MOSES, Assistant Examiner US. Cl. X.R.

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