BRACKETRY FOR CEILING FAN OR LAMP RETROFITS AND METHOD OF INSTALLING SAME

Abstract

Bracketry comprising an L-bracket, a T-bracket, and a joist hanger assembly, and methods of installation of the bracketry that eliminate the need to install a heavier duty electrical junction box and the difficulty of removing and reinstalling wiring in a new electrical junction box or fabricate bracing structure at the jobsite when performing a heavy ceiling fan or lighting fixture retrofit have been presented. The bracketry and installation methods are intended to reduce the cost and complexity of performing a retrofit installations.

Claims

1. A ceiling fixture mount comprising: a T-shaped bracket, a joist and an electrical junction box; the T-shaped bracket comprising: an angle element having a first leg, a second leg, and a fixture element; wherein the electrical junction box is disposed between the first leg of the angle element and the joist; wherein the first leg of the angle element is attached to the joist with fasteners that pass through the electrical junction box; wherein the first leg of the angle element includes countersunk holes for the fasteners, wherein the countersinks are on a side of the first leg which faces the joist; wherein the fixture element is removably attachable to the second leg of the angle element via fasteners; and wherein the fixture element is removably attachable to a ceiling fixture.

2. A ceiling fixture mount comprising: an L-shaped bracket, a joist and an electrical junction box; wherein the L-shaped bracket comprises a first arm and a second arm; wherein the electrical junction box is disposed between the first arm and the joist; wherein the first arm includes countersunk holes for the fasteners, wherein the countersink are on a side of the first arm which faces the joist; wherein the first arm of the L-shaped bracket is attached to the joist by fasteners that pass through the electrical junction box; and wherein the second arm of the L-shaped bracket is attachable to a ceiling fixture.

3. A ceiling mount comprising: a hanger rod; a cross brace, a fixture interface bracket, an electrical junction box and two joists; wherein the hanger rod passes through a hole formed in the electrical junction box and is secured to the cross brace at one end and to the fixture interface bracket at another end; wherein the cross brace is secured to one of the two joists at one end and to the other of the two joists at another end; and wherein the fixture interface bracket is removably attachable to a ceiling fixture.

4. A ceiling mount comprising: a cross-bracket, a joist attachment bracket, an electrical junction box and two joists; wherein the cross-bracket is rotatably attached to the joist attachment bracket; wherein the joist attachment bracket is secured to one of the two joists at one end and to the other of the two joists at another end; and wherein the cross-bracket is removably attachable to the cross-bracket and removably attachable to a ceiling fixture.

5. A method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist, comprising the steps of: removing an existing ceiling fixture; supplying a T-shaped bracket, wherein the T-shaped bracket comprises an angle element and a fixture element, the fixture element being removably attachable to the angle element, the angle element having a first leg, the first leg being attachable to the joist, the fixture element being attachable to a ceiling fixture; positioning the T-shaped bracket inside the junction box such that the first leg of the angle element is disposed adjacent to a wall of the junction box adjacent to a joist, wherein an end of the fixture element extends outside the junction box onto the ceiling; scribing a line on the ceiling around a portion of the end of the fixture element located on the ceiling; removing the T-shaped bracket from the junction box; cutting out the ceiling interior of the scribed line; disassembling the T-shaped bracket; placing the angle element inside the junction box; attaching the angle element to the joist from inside the junction box; securing the fixture element to the angle element; and attaching a ceiling fixture to the fixture element.

6. The method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist of claim 5, further comprising the step of moving wiring disposed within the junction box to create space for the T-shaped bracket.

7. The method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist of claim 5, wherein the angle element is attachable to the joist by means of screws, wherein the screws pass through holes in the first leg of the angle element and are driven through a side wall of the junction box and into the joist.

8. The method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist of claim 7, wherein the holes in the first leg of the angle element are countersunk and wherein the countersink is on a side of angle element which abuts the side wall of the junction box.

9. The method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist of claim 5, wherein the fixture element is removably attachable to the angle element by means of threaded screws.

10. A method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist, comprising the steps of: removing an existing ceiling fixture; supplying an L-shaped bracket, wherein the L-shaped bracket comprises a first arm and a second arm, the first arm being attachable to the joist, the second arm being attachable to a ceiling fixture; positioning the L-shaped bracket inside the junction box such that the first arm is disposed adjacent a wall of the junction box adjacent to a joist, wherein an end of the second arm extends outside the junction box onto the ceiling; scribing a line on the ceiling around the end of the second arm located on the ceiling; cutting out the ceiling interior of the scribed line; attaching the first arm to the joist from inside the junction box; and attaching a ceiling fixture to the second arm.

11. The method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist of claim 10, further comprising the step of moving wiring disposed within the junction box to create space for the L-shaped bracket.

12. The method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist of claim 10, wherein the means for attaching to the joist comprises holes in the first arm and screws, whereby the screws are driven through a side wall of the junction box and into the joist.

13. The method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist of claim 12, wherein the holes in the first arm are countersunk and wherein the countersink is on a side of the first arm which abuts the side wall of the junction box.

14. The method for installing a ceiling fixture in a ceiling having a junction box disposed adjacent to a joist of claim 10, wherein the fixture is attachable to the second arm by means threaded holes and screws.

15. A method for installing a ceiling fixture in a ceiling having a junction box disposed between two joists, comprising the steps of: removing an existing ceiling fixture; supplying a hanger rod, a cross brace attachable to an end of the hanger rod, and a fixture interface bracket attachable to an end of the hanger rod, the fixture interface bracket attachable to a ceiling fixture; drilling a hole in the junction box; attaching the fixture interface bracket to an end of the hanger rod; positioning the cross brace across the two joists and above the junction box; inserting a free end of the hanger rod through the hole in the junction box; securing the free end of the hanger rod to the cross brace; and attaching a ceiling fixture to the fixture interface bracket.

16. The method for installing a ceiling fixture in a ceiling having a junction box disposed between two joists of claim 15, further comprising the step of securing the cross brace to the joists.

17. The method for installing a ceiling fixture in a ceiling having a junction box disposed between two joists of claim 15, after the step of attaching the fixture interface bracket to an end of the hanger rod and, after the step of inserting a free end of the hanger rod through the hole in the junction box, further comprising the step of temporarily securing the fixture interface bracket to the junction box until the free end of the hanger rod is secured to the cross brace.

18. A ceiling fixture mount comprising: a T-shaped bracket, a joist and an electrical junction box; the T-shaped bracket comprising: an angle element having a first leg, a second leg, and a fixture element; wherein the electrical junction box is disposed between the first leg of the angle element and the joist; wherein the first leg of the angle element is attached to the joist with fasteners that pass through the electrical junction box; wherein the fixture element is removably attachable to the second leg of the angle element; and wherein the fixture element is attachable to a ceiling fixture.

19. The ceiling fixture mount of claim 18, wherein the first leg of the angle element includes countersunk holes for the fasteners, wherein the countersink is on a side of the first leg which faces the joist.

20. The ceiling fixture mount of claim 18, wherein the fixture element is removably attachable to the second leg of the angle element by means of fasteners.

21. A ceiling fixture mount comprising: an L-shaped bracket, a joist and an electrical junction box; wherein the L-shaped bracket comprises a first arm and a second arm; wherein the electrical junction box is disposed between the first arm and the joist; wherein the first arm of the L-shaped bracket is attached to the joist by fasteners that pass through the electrical junction box; and wherein the second arm of the L-shaped bracket is attachable to a ceiling fixture.

22. The ceiling fixture mount of claim 21, wherein the first arm includes countersunk holes for the fasteners, wherein the countersink is on a side of the first arm which faces the joist.

23. A hanger assembly for use in installing ceiling fixtures in an existing electrical junction box disposed between two joists, the assembly comprising: a hanger rod; a cross brace attachable to an end of the hanger rod; a fixture interface bracket attachable to another end of the hanger rod; wherein the hanger rod passes through the electrical junction box; and wherein the fixture interface bracket attachable to a ceiling fixture.

24. A method for installing a ceiling fixture in a ceiling having an electrical junction box disposed between two joists, comprising the steps of: providing a cross-bracket rotatably attached to a joist attachment bracket; removing an existing ceiling fixture to expose a previously installed electrical junction box; locating ceiling joists closest to the electrical junction box; attaching the cross bracket to the electrical junction box; positioning the joist attachment bracket such that it spans the previously located joists; scribing a line in the ceiling around the joist attachment bracket; removing the cross-bracket and attached joist attachment bracket from the junction box; forming a cutout in the ceiling following the scribe line; reattaching the cross-bracket and attached joist attachment bracket to the electrical junction box; and securing the joist attachment bracket to the joists.

25. The method for installing a ceiling fixture in a ceiling having a junction box disposed between two joists of claim 24, further comprising the step of attaching a ceiling fixture to the joist attachment bracket.

26. The method for installing a ceiling fixture in a ceiling having a junction box disposed between two joists of claim 25, patching the cutout in the ceiling.

27. A ceiling fixture mount comprising: an L-shaped bracket, a joist and an electrical junction box; wherein the L-shaped bracket comprises a long arm and a short arm; wherein the long arm includes at least one countersunk hole and the short arm includes at least one clearance hole; wherein at least one gusset is attached to the long arm; wherein the electrical junction box is disposed between the short arm and the joist; wherein the L-shaped bracket is attached to the joist by at least one fastener that passes though the at least one countersunk hole and the at least one clearance hole; and wherein the long arm of the L-shaped bracket is attachable to a ceiling fixture.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0031] FIG. 1A is a front perspective view of the L-bracket of the present invention.

[0032] FIG. 1B is a rear perspective view of the L-bracket of the present invention.

[0033] FIG. 2A is a front perspective view of the T-bracket of the present invention.

[0034] FIG. 2B is a rear perspective view of the T-bracket of the present invention.

[0035] FIG. 2C is an exploded, front perspective view of the T-Bracket of FIG. 2A.

[0036] FIG. 3A is a perspective view of the joist hanger assembly of the present invention.

[0037] FIG. 3B is a top view the fixture interface bracket of the joist hanger assembly of FIG. 3A.

[0038] FIG. 3C is a side view of the fixture interface bracket of the joist hanger assembly of FIG. 3A.

[0039] FIG. 3D is a top view of the cross brace of the joist hanger assembly of FIG. 3A.

[0040] FIG. 3E is side view of the cross brace of the joist hanger assembly of FIG. 3A.

[0041] FIG. 4A is a front perspective view of the L-bracket of FIG. 1A showing the wood screws used to attach the L-bracket to a joist.

[0042] FIG. 4B is a perspective view of a ceiling and an electrical junction box installed therein, partially cutaway to show adjacent joists.

[0043] FIG. 4C is a perspective view of the L-bracket of FIG. 1A held within the junction box depicted in FIG. 4A showing an installer scribing a line about a portion of the L-bracket.

[0044] FIG. 4D is a perspective view showing an installer cutting out a portion of ceiling drywall interior of the scribe line depicted in FIG. 4C.

[0045] FIG. 4E is a perspective view showing a cutout in the ceiling drywall, interior of the scribe line of FIG. 4C.

[0046] FIG. 4F is a perspective showing an installer attaching the L-bracket of FIG. 4A to a joist in a ceiling by driving the wood screws through a pre-existing electrical junction box.

[0047] FIG. 4G is cross-sectional view showing an L-bracket attached to a joist through the wall of an electrical junction box.

[0048] FIG. 4H is a perspective view showing the L-bracket of FIG. 1 installed in a ceiling.

[0049] FIG. 4I is a perspective view showing a representative mounting bracket for a retrofit fan or lighting fixture attached to the L-bracket of FIG. 1A, installed in a ceiling.

[0050] FIG. 5A is an exploded front perspective view of the T-bracket of FIG. 2A showing the wood screws used to attach the T-bracket to a joist.

[0051] FIG. 5B is a perspective view of the T-bracket of FIG. 2A held within a junction box showing an installer scribing a line about a portion of the T-bracket.

[0052] FIG. 5C is a perspective view showing an installer cutting out a portion of ceiling drywall interior of the scribe line depicted in FIG. 5B.

[0053] FIG. 5D is a perspective view of an installer holding a T-bracket of the present invention disassembled into its angle element and fixture element components.

[0054] FIG. 5E is a perspective showing an installer attaching the angle element of FIG. 5D to a joist in a ceiling by driving the screws through a pre-existing electrical junction box.

[0055] FIG. 5F is cross-sectional view showing the angle element of the T-bracket attached to a joist through the wall of an electrical junction box.

[0056] FIG. 5G is a perspective view showing the fixture element of the T-bracket being attached to the angle element of the bracket, by an installer.

[0057] FIG. 5H is a perspective view showing the T-bracket of FIG. 2A installed in a ceiling.

[0058] FIG. 5I is a perspective view showing a representative mounting bracket for a retrofit fan or lighting fixture attached to the T-bracket of FIG. 2A, installed in a ceiling.

[0059] FIG. 6A is a schematic view of an installer drilling a clearance hole in a ceiling mounted electrical junction box.

[0060] FIG. 6B is a perspective view of preexisting junction box, installed in a ceiling, with a clearance hole drilled in the box.

[0061] FIG. 6C is a perspective view of a hanger rod and an attached fixture interface bracket in accordance with the present invention being inserted through the clearance hole in a junction box, depicted in FIG. 6B.

[0062] FIG. 6D is a perspective view of an installer attaching the hanger rod and attached fixture interface bracket of FIG. 6C to a junction box with a temporary screw.

[0063] FIG. 6E is a perspective view of the hanger rod and fixture interface bracket of FIG. 6C attached to a cross brace in accordance with the present invention, where the cross brace spans ceiling framing structure.

[0064] FIG. 6F is an enlarged view of showing the hanger rod attachment to the cross brace of FIG. 6E.

[0065] FIG. 6G is a schematic view of an installer securing an end of the cross brace of FIG. 6E to ceiling framing structure.

[0066] FIG. 6H is a schematic view showing a representative fixture mounting bracket of a retrofit fixture attached to the fixture interface bracket of the present invention.

[0067] FIG. 7A is a top view of a joist attachment bracket for use with the cross-bracket assembly of the present invention.

[0068] FIG. 7B is a side view of a joist attachment bracket for use with the cross-bracket assembly of the present invention.

[0069] FIG. 7C is a top view of a cross-bracket for use with the cross-bracket assembly of the present invention.

[0070] FIG. 7D is a side view of a cross-bracket for use with the cross-bracket assembly of the present invention.

[0071] FIG. 7E is a perspective view of a spacer for use with the cross-bracket assembly of the present invention.

[0072] FIG. 7F is a perspective view of the cross-bracket assembly of the present invention.

[0073] FIG. 7G is a perspective view of an installer removing a ceiling fixture to expose an electrical junction box in a ceiling.

[0074] FIG. 7H is a perspective view of an installer locating ceiling joists in proximity to the junction of box of FIG. 7G.

[0075] FIG. 7I is a perspective view of an installer attaching the cross-bracket and joist attachment bracket of the present invention to an electrical junction box of FIG. 7G.

[0076] FIG. 7J is a perspective view of an installer marking a line around the joist attachment bracket of the present invention after it has been position across the joists located in FIG. 7H.

[0077] FIG. 7K is a perspective view of an installer cutting out drywall in a ceiling along the line marked in FIG. 7J.

[0078] FIG. 7L a perspective view of an installer making a notch in an electrical junction box shown in FIG. 7G to provide clearance for the joist attachment bracket of the present invention.

[0079] FIG. 7M a perspective view of an installer re-attaching the cross-bracket and joist attachment bracket of the present invention to the electrical junction box of FIG. 7G.

[0080] FIG. 7N a perspective view of an installer attaching the joist attachment bracket of the present invention to the joists located in FIG. 7H.

[0081] FIG. 7O a perspective view of an installer attaching a ceiling fixture to the joist attachment bracket of the present invention using spacers and fasteners.

[0082] FIG. 7P a perspective view of an installer patching the cutout in the ceiling drywall made in FIG. 7K.

[0083] FIG. 8A is a rear perspective view of an L-bracket with gussets.

[0084] FIG. 8B is a front perspective view of an L-bracket with gussets.

[0085] FIG. 8C a cross-sectional view taken along the line-8-8 of FIG. 8A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0086] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. The invention however, may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

[0087] The present invention comprises bracketry and installation methods for use in retrofitting heavy ceiling fans or ceiling lighting fixtures. The bracketry and methods presented allow installers to use pre-existing standard or light duty electrical junction boxes and thereby eliminate the need to install and wire a heavy duty junction box or fabricate custom bracing at a job site. More specifically, the embodiments include an L-bracket 10 and method of installation, a T-bracket 20 and method of installation and, a joist hanger assembly 30 and method of installation.

The L-Bracket

[0088] With reference to FIGS. 1A, 1B and 4A, the L-bracket 10 of the present invention includes a first arm 12 and a second arm 14. The first arm 12 of the L-bracket 10 includes two countersunk mounting holes 16, which allow the L-bracket 12 to be mounted to a joist 24 via wood screws 26 (see FIG. 4A). The countersunk holes 16 are through-holes. The use of countersunk holes allows the wood screws 26 to be installed at an angle. It should be noted that the countersinks 17 are placed on a side of the first arm 12 that abuts a junction box 36, i.e. on the side opposite the side from which the wood screws 26 first pass through the first arm 12 of the L-bracket 10. (See FIG. 4A.)

[0089] The second arm 14 of the L-bracket 10 includes three fixture bracket mounting holes 18 and a ground screw hole 22. The fixture bracket mounting holes 18 are drilled and tapped with screw threads, as is the ground screw hole 22. The fixture mounting bracket holes 18 are spaced to be compatible with the hole spacing of standard heavy duty electrical junction boxes, which correspond to the mounting hole spacing on most mounting brackets included with heavy ceiling fans or lighting fixtures. To reduce snagging on wiring, the long arm 14 of the L-bracket 10 may optionally include radiused corners 28.

[0090] The L-bracket is suitable for mounting ceiling fans and heavy lighting fixtures to a joist, regardless of whether the joist is accessible from above the ceiling. In the exemplary embodiment, the L-bracket 10 is fabricated from 3/16 steel flat stock. The second arm 14 is approximately 4 long by 1 wide and, the first arm 12 is approximately 2 long by 1 wide. The mounting holes 16 in the first arm 12 are diameter through-holes with a countersink. The fixture bracket mounting holes 18 in the second arm 14 are 10-32 threaded holes. The radiused ends 28 have a 0.187 radius. The above dimensions are provided for reference only. The utility of the L-bracket is not dependent on any particular dimensions or on any particular type of material. The bracket's dimensions and materials can vary from those provided above, while still allowing the bracket to serve its intended purpose.

Installation of the L-Bracket

[0091] With reference to FIGS. 4A to 4I, installation of the L-bracket in an exemplary ceiling fan or lighting fixture retrofit installation in a representative ceiling will be described in more detail. FIGS. 4B-4I show, in schematic form, among other items, a representative drywall ceiling 34, a representative electrical junction box 36, representative junction box wiring 38, and representative ceiling framing joists 24.

[0092] With reference to FIG. 4B, in step 1, the preexisting ceiling fan or lighting fixture 32 (not shown) is removed from the ceiling. In step 2, upon removal of the preexisting fixture 32, the wiring 38 in the electrical junction box 36 is moved to one side, if necessary, to make room for the L-bracket 10.

[0093] With reference to FIG. 4C, in step 3, the L-bracket 10 is placed within the junction box 36. The first arm 12 of the L-bracket 10 is positioned against a wall of the junction box on the side adjacent the joist 24. In this position, a free end 40 of the second arm 14 of the L-bracket 10 extends over the ceiling drywall 34. An installer marks a scribe line 42 around the free end 40 of the second arm 12.

[0094] With reference to FIG. 4D, in step 4, an installer notches or cuts out the ceiling drywall 34 interior of the scribe line 42 to form a cutout 44 in the ceiling drywall 34. (See FIG. 4E.) The cutout 44 allows the L-bracket 10 to be mounted flush with the ceiling drywall 34.

[0095] With reference to FIGS. 4A, 4F and 4G, in step 4, the installer attaches the L-bracket 10 to the ceiling joist 24 by driving wood screws 26 through the countersunk mounting holes 16, through the wall of the junction box 36, and into the joist 24. FIG. 4A illustrates the wood screws 26 and FIG. 4G depicts the L-bracket attached to the joist 24. Experimentation has demonstrated that wood screws can be driven though plastic junction boxes without the need for pilot holes. Pilot holes may be necessary in the case of a sheet metal junction box.

[0096] With reference to FIGS. 4H and 4I, in step 5, a ceiling fan or lighting fixture mounting bracket 46 (shown in schematic form) is installed on the L-bracket 10 with threaded screws 48. The spacing of the threaded fixture mounting holes 18 corresponds to that of the mounting brackets for most commercially available heavy ceiling fans and lighting fixtures. The L-bracket 10 is equipped with a threaded hole 22 for a ground wire (see FIGS. 1A and 1B), which may be required in some installations.

L-BracketAlternative Embodiment

[0097] FIGS. 8A to 8C show an alternative embodiment of an L-bracket 11.

[0098] The alternative L-bracket 11 includes a long arm 140, a short arm 142 and gussets 144 (i.e. at least one gusset). The at least one gusset 144 stiffens the alternative L-bracket 11 and provides increased mounting strength. Formed on the long arm 140 are first and second countersunk holes 148 and 149, (i.e. at least one countersunk hole). Formed on the short arm 142 are first and second clearance holes 146 and 147, (i.e. at least one clearance hole), which function in conjunction with the first and second countersunk holes 148 and 149 to attach the alternative L-bracket 11 to a ceiling joist 24. The long arm 140 also includes threaded fixture bracket mounting holes 156. The corners of the long arm 140 and short arm 142 may, optionally, be radiused to reduce sharp edges. The alternative L-bracket 11 may also, optionally, include a hole for a ground screw.

[0099] In the exemplary embodiment, the alternative L-bracket 11 is made from a single piece of 12 gauge sheet metal cut and formed to shape. The first and second countersunk holes 148 and 149 formed in the long arm 140 allow the heads of first and second wood screws 150 and 151 to be flush with the surface of the bracket. Exemplary dimensions for the alternative L-bracket 11 are as follows: The long arm 140 is approximately 4 inches long by 1.2 inches wide. The short arm 142 is approximately 2.2 inches tall by 1.4 inches wide. The gussets 144 are approximately 3 inches in length at their junction with the long arm 140 and are approximately 1 inch in height. The first and second countersunk holes 148 and 149 are approximately inch in diameter and the first and second clearance holes 146 and 147 are approximately 7/16 inch in diameter. The fixture bracket mounting holes 156 are 10-32 threaded holes. The above dimensions are provided for reference only. The utility of the alternative L-bracket 11 is not dependent on any particular dimensions or on any particular type of material. The bracket's dimensions and materials can vary from those provided above, while still allowing the bracket to serve its intended purpose.

Installation of the L-Bracket Alternative Embodiment

[0100] Installation of the alternative L-bracket 11 is generally similar to that of the L-bracket 10 and reference will be made to FIGS. 4B to 4I and 8C. In step 1, a preexisting ceiling fan or lighting fixture is removed from the ceiling. In step 2, wiring in the electrical junction box 36 is moved to one side, as may be necessary, to make room for the alternative L-bracket 11. (See FIG. 4B.) In step 3, the alternative L-bracket 11 is placed within the electrical junction box 36. (See FIG. 4C.) The short arm 142 is positioned against a wall of the junction box on a side adjacent a joist 24. In this position, a free end of the long arm 140 may extend over the ceiling drywall 34. If such is the case, an installer marks a scribe line 42 around the free end of the long arm 140.

[0101] In step 4, an installer notches or cuts out the ceiling drywall 34 interior of the scribe line 42 to form a cutout 44 in the ceiling drywall 34. (See FIGS. 4D and 4E.) The cutout 44 allows the alternative L-bracket 11 to be mounted flush with the ceiling drywall 34.

[0102] With reference to FIG. 8C, in step 5, the installer attaches the alternative L-bracket 11 to the ceiling joist 24 by inserting the first wood screw 150 through the first countersunk hole 148 and through the first clearance hole 146. Thereafter, the first wood screw 150 is driven through the electrical junction box 36 and into the wood ceiling joist 24. Next, the installer inserts the second wood screw 151 through the second countersunk hole 149 and through the second clearance hole 147. As with the first wood screw 150, the second wood screw 151 is driven through the electrical junction box 36 and into the wood ceiling joist 24. Upon both the first and second wood screws 150 and 151 being driven into the ceiling joist 24, the alternative L-bracket 11 is securely fastened to the ceiling joist 24.

[0103] Experimentation has demonstrated that wood screws can be driven though plastic junction boxes without the need for pilot holes. Pilot holes may be necessary in the case of a sheet metal junction box. Due to the geometry of the alternative L-bracket 11, the second wood screw 151 may be shorter than the first wood screw 150.

[0104] In step 6, a ceiling fan or lighting fixture mounting bracket 48 (shown in schematic form) is installed on the alternative L-bracket 11 with threaded screws. FIG. 4I is illustrative. (FIG. 4I specifically references the L-bracket 10, however, the alternative L-Bracket 11 attaches to the fixture bracket 48 in the same manner, i.e. via screws.

The T-Bracket

[0105] With reference to FIGS. 2A-2C and 5A, the T-bracket 20 of the present invention comprises an angle element 50 and a fixture element 52. The angle element 50 serves to mount the T-bracket 20 to a joist 24 and the fixture element 52 serves to attach the mounting bracket 46 of a ceiling fan or lighting fixture to the T-bracket 20. The angle element 50 has a first leg 53 and a second leg 55. The second leg 55 is removably attachable to the fixture element 52 via threaded holes 65 and screws 64.

[0106] Similar to the L-bracket 10, the first leg 53 of the angle element 50 of the T-bracket 20 includes two countersunk mounting holes 54. Unlike conventional countersunk holes, the countersinks 57 are positioned on a side of the first leg 53 which abuts the junction box, i.e. on a side opposite the side the wood screws 26 first pass through the holes 54 in the first leg. (See FIG. 5A.) This unusual placement of the countersinks 57 allows the wood screws 26 to be installed at an angle.

[0107] The fixture element 52 of the T-bracket 20 has a first end 60 and a second end 62, where the first and second ends 60 and 62, each include (optional) radiused corners 58. The fixture element 52 includes two threaded fixture bracket mounting holes 56 and a threaded ground screw hole 63. The fixture element holes 56 are spaced to be compatible with the hole spacing of common heavy duty electrical junction boxes, which correspond to the mounting hole spacing on most mounting brackets included with heavy ceiling fans or lighting fixtures.

[0108] Like the L-bracket 10, the T-bracket 20 is suitable for mounting heavy ceiling fans and heavy lighting fixtures to a joist, regardless of whether the joist is accessible from above the ceiling. The T-bracket 20 places the centerline of the load of such retrofit fixtures closer to the joist 24 and therefore, generally, has a higher load capacity than the L-bracket 10.

[0109] In an exemplary embodiment, the T-bracket 20 is fabricated from 3/16 steel flat stock. The fixture element 52 is approximately 3.75 long by 1 wide. With respect to the angle element 50, the first leg 53 is approximately 2 long by 1 wide and the second leg 55 is approximately 1.25 long by 1 wide. The mounting holes 54 in the angle element 50 are diameter through-holes with a countersink. The fixture element mounting holes 56 are 10-32 threaded holes. The radiused corners 58 of the fixture element 52 have a 0.187 radius. The angle element 50 and the fixture element 52 are removably attachable by means of threaded screws and threaded holes. Testing of the above-referenced exemplary embodiment has shown that it can support a fixture weight of at least 180 lbs.

[0110] The above dimensions for the T-bracket are provided for reference only. The utility of the T-bracket is not dependent on any particular dimensions or on any particular type of material. The bracket's dimensions and materials can vary from those provided above, while still allowing the bracket to serve its intended purpose. The weight the bracket can support will vary with material type and specific choice of dimensions.

Installation of the T-Bracket

[0111] With reference to FIGS. 5A to 5I, installation of the T-bracket 20 in an exemplary ceiling fan or lighting fixture retrofit installation in a representative ceiling will be described in more detail. Depicted in the figures are, among other items, a representative drywall ceiling 34, a representative electrical junction box 36, representative junction box wiring 38, and representative framing joists 24.

[0112] In step 1, the preexisting ceiling fan or lighting fixture 32 (not shown) is removed from the ceiling. With reference to FIG. 4B, in step 2, upon removal of the preexisting fixture 32, the wiring 38 in the electrical junction box 36 is moved to one side, if necessary, to make room for the T-bracket 20.

[0113] With reference to FIG. 5B, in step 3, the T-bracket 20 is placed within the junction box 36. The angle element 50 of the T-bracket 20 is positioned against a wall of the junction box on the side adjacent the joist 24. In this position, a first end 62 of the fixture element 52 extends over the ceiling drywall 34. An installer marks a scribe line 43 around the first end 62 of the fixture element 52.

[0114] With reference to FIG. 5C, in step 4, an installer notches or cuts out the ceiling drywall 34 interior of the scribe line 43 to form a cutout 66 (see FIG. 5E) in the ceiling drywall 34. The cutout 66 allows the T-bracket 20 to be mounted flush with the ceiling drywall 34.

[0115] With reference to FIG. 5D, in step 5, the installer removes the T-bracket from the junction box and disassembles the bracket into its two component parts, the angle element 50 and fixture element 52.

[0116] With reference to FIGS. 5E-5F, in step 6, the installer attaches the angle element 50 of the T-bracket 20 to the ceiling joist 24 by driving wood screws 26 through the countersunk mounting holes 54, through the wall of the junction box 36, and into the joist 24. This attachment is shown in detail in FIG. 5F. Generally, the installer will drive the wood screws through the side wall of the junction box 36 and into the adjacent joist 24 without first drilling pilot holes. This is typically the case when the preexisting junction box is made of plastic. If the preexisting junction box is made of sheet metal, pilot holes may be necessary.

[0117] With reference to FIG. 5G, in step 7, the fixture element 52 is attached to the angle element 50 by means of screws 64 which pass through holes 61 in the fixture element 52 and engage threaded holes 65 in the angle element 50. With reference to FIGS. 5H and 5I, a ceiling fan or lighting fixture mounting bracket 46 (shown schematically) is installed on the T-bracket 20 with threaded screws. The spacing of the fixture mounting holes 56 corresponds to that of the mounting brackets for most commercially available heavy ceiling fans and lighting fixtures. The T-bracket 20 is also equipped with a threaded hole 62 for a ground wire (see FIGS. 2A and 2B), which may be required in some installations.

The Joist Hanger Assembly

[0118] With reference to FIGS. 3A through 3E, the joist hanger assembly 30 comprises a cross brace 68, a hanger rod 72, a fixture interface bracket 74 and assembly hardware, i.e. nuts 90 and washers 92. The cross brace 68 is fabricated from angle stock and includes a plurality of holes 70, which may be uniformly spaced along a length of the cross brace 68. The hanger rod 72 is fabricated from threaded rod of a preselected threading. The holes 70 of the cross brace 68 are sized so as to be clearance holes for the hanger rod 72. The fixture interface bracket 74 is fabricated from sheet or bar stock and includes a raised center portion 84, downwardly angled portions 86 and horizontal mounting portions 88. The fixture interface bracket further includes a center hole 76 sized as a clearance hole for the hanger rod 72, heavy ceiling fan or lighting fixture bracket attachment holes 78, where the fixture bracket attachment holes 78 are spaced to match the attachment holes found in both 3 and 4 heavy duty electrical junction boxes. This hole spacing also corresponds to the mounting bracket spacing for most heavy ceiling fans and lighting fixtures.

[0119] In an exemplary embodiment, the cross brace 68 is fabricated from 1 by 1 steel angle with diameter holes spaced 1 apart. The hanger rod 72 is fabricated from threaded steel rod and the fixture interface bracket is fabricated from 3/32 steel bar stock. A joist hanger assembly fabricated using the above referenced materials and with a joist spacing of about 18 has been found to support a weight of at least 180 pounds or well in excess of the weight of most common ceiling fans or lighting fixtures. The dimensions and materials used in the exemplary embodiment of the joist hanger assembly 30 of the present invention presented here are not meant to be limiting. Alternative materials and dimensions are also suitable. Alternative materials would include aluminum and structural plastics.

Installation of the Joist Hanger Assembly

[0120] The joist hanger assembly 30 may be used where there is sufficient space above the joists to place the cross brace 68. Referring to FIGS. 6A to 6H, installation of the joist hanger assembly 30 in an exemplary ceiling fan or lighting fixture retrofit installation in a representative ceiling will be described in more detail. Depicted in the figures are, among other items, a representative drywall ceiling 34, a representative electrical junction box 36, representative junction box wiring 38, and representative framing joists 24.

[0121] In step 1, the preexisting ceiling fan or lighting fixture (not shown) is removed from the ceiling. With reference to FIGS. 6A and 6B, in step 2, electrical wiring is moved out of the way so that an installer may drill a clearance hole 96 in the center of an electrical junction box. In step 3, the installer drills a center hole or clearance hole 96. FIG. 6A references the installer drilling the clearance hole 96 and FIG. 6B shows the clearance hole 96 drilled in the junction box 36.

[0122] With reference to FIG. 6C, in step 4, an installer assembles the fixture interface bracket 74 to the hanger rod 72 with two nuts 90, as depicted in FIG. 6C. With reference to FIGS. 6C and 6D, in step 5, the installer inserts the hanger rod 72, with the fixture interface bracket 74 attached, into the clearance hole 96 in the electrical junction box 36 and secures the hanger rod and attached fixture interface bracket with a temporary screw 98. The temporary screw 98 passes through a hole 82 in the fixture interface bracket (see FIG. 6D) and into the side wall of the junction box 36. The temporary screw 98 is referred to as a temporary screw as it serves to secure the hanger rod 72 and fixture interface bracket 74 to the junction box 36 only for so long as is needed to complete the installation of the joist hanger assembly 30. The temporary screw 98 is removed prior to the installation of a retrofit ceiling fan or lighting fixture.

[0123] With reference to FIGS. 6E and 6F, in step 6, the cross brace 68 is positioned across adjacent joists 24 such that a free end of the hanger rod 72 protrudes from one of the plurality of holes 70 in the cross brace 68. In step 7, the hanger rod 72 is secured to the cross brace 68 by means of a nut 90, with a washer 92 disposed between the nut 90 and the cross brace 68. During this step, the nut 90 is tightened such that the fixture interface bracket 74 is held snug against the electrical junction box 36.

[0124] With reference to FIG. 6G, in step 8, the cross brace 68 is secured to the joists 24 with a fastener 100. With reference to FIG. 6H, the temporary screw 98 is removed and a mounting bracket 46 of a retrofit ceiling fan or lighting fixture may be installed via threaded screws.

The Cross-Bracket Assembly

[0125] With reference to FIGS. 7A to 7F, the cross-bracket assembly 102 comprises a joist attachment bracket 104 and a cross bracket 112, wherein the cross-bracket 110 is rotateably attachable to the joist attachment bracket 104. The joist attachment bracket 104 is flat bracket having a length sized to span the distance between ceiling joists and a width and thickness sized to support a relatively heavy ceiling fixture. Typically, the joist attachment bracket will be made of steel flat stock and will have a length of about 18 inches, a width of about 1 inch and a thickness of about 3/16 inch. The length corresponds to ceiling joist spacing which is about 18 inches in modern residential construction in the United States. Other lengths may prove desirable and necessary in any building where non-standard ceiling joist spacing was used. A joist attachment bracket of approximately 1 inch width and 3/16 inch thickness provides sufficient strength to support most ceiling fixtures. The materials and dimensions specified above are exemplary only. Other dimensions and materials are suitable.

[0126] The joist attachment bracket 104 includes a plurality of threaded holes 106 which are spaced along a longitudinal centerline of the bracket, and includes slots 108 at each end of the bracket. The slots 108 allow the joist attachment bracket 104 to be attached to joists 24 via a fastener 116, which will typically be a wood screw. The slots 108 allow the fastener 116 to be installed at the approximate center of a joist 24

[0127] The cross-bracket 110 is also a flat bracket having a length sized to span the diameter of an electrical junction box 36. In the exemplary embodiment, the cross bracket is fabricated from steel and has a width of and a thickness of 1/16. It should be noted however, that the cross bracket 110 does not carry substantial loads and can be fabricated with a variety of dimensions and from a variety of materials. The cross-bracket 110 includes a center hole 112 which allows it to be attached via a fastener 118 to one of the plurality of holes 106 in the joist attachment bracket 104. Typically, the fastener 118 will be a machine screw. Ends of the cross-bracket 110 include slots 114 which are used to attach the cross bracket 110 to existing holes in electrical junction box 36 via fasteners 120. The fasteners 120 will typically be machine screws. The slots 114 provide adjustability to accommodate a variety of ceiling fixture bolt patterns.

[0128] Spacers 136 may be required during installation of the cross-bracket assembly 102. FIG. 7E depicts an exemplary embodiment of a suitable spacer.

Installation of the Cross-Bracket Assembly

[0129] The cross-bracket assembly 102 is attached to a ceiling, generally, as follows. With reference to FIG. 7G, in a first step, an installer first removes an existing ceiling fixture 122 which will expose a previously installed electrical junction box 36. With reference to FIG. 7H, in a second step, the installer next locates the ceiling joists 24 (not visible in this view) closest to the junction box 36 with a joist location device 124. The joist location device 124 may be an electronic device such as commercially available stud finders that use capacitance, radar or other technologies to locate studs, or, alternatively, the joists may be located with a screw driver or like tool, as is known to those of skill in the art.

[0130] With reference to FIGS. 7I and 7J, in a third step, the cross-bracket 110 is assembled to the joist attachment bracket 104 via a fastener 118 and, in a fourth step, the installer attaches the cross bracket 110 to the junction box 36, via fasteners 120. If necessary, the installer may move the preexisting wiring 38 out of the way to provide clearance for the cross bracket 110. In a fifth step, the joist attachment bracket 104 is then positioned such that it spans the previously located joists 24 on each side of the junction box 36. In a sixth step, the installer then scribes a line 126 around the joist attachment bracket 104. (See FIGS. 7J and 7k.)

[0131] With reference to FIGS. 7K and 7L, in a seventh step, the cross-bracket 110 and attached joist attachment bracket 104 are removed from the junction box 36 and the installer following the scribe line 126, forms a cutout 128 (see FIG. 7L) in the ceiling drywall 34 with a first cutting tool 132. The cutout 128 serves to expose the ceiling joists 24. In an eighth step, notches 130 are then cut in the electrical junction box 36 with a second cutting tool 134. The notches 130 allow the joist attachment bracket 104 to lay flat across the junction box 36 and the joists 24, when installed.

[0132] With reference to FIG. 7M, in a ninth step, the cross-bracket 110 with the joist attachment bracket 104 attached, is reattached the electrical junction box 36 via fasteners 120. During this step, the joist attachment bracket 104 is positioned so that it lays within the cutout 128 and is flat across the junction box 36 and the exposed joists 24. With reference to FIG. N, in a tenth step, the installer secures the joist attachment bracket 104 to the joists 24 via fasteners 116.

[0133] With reference to FIG. 7O, in an eleventh step, a new ceiling fixture or fixture bracket 46 is attached to the joist attachment bracket 104 by means of spacers 136 (where needed) and fasteners 116. With reference to FIG. 7P, in a twelfth step, in a typical, installation, the cutout 128 in the ceiling drywall 34 will be patched with drywall patching 160 for aesthetic reasons, using commercially available drywall patching materials known to those of skill in the art.

[0134] Bracketry and methods of installation of the bracketry that eliminate the need to install a heavy duty junction box or fabricate bracing structure at the jobsite when performing a ceiling fan or lighting fixture retrofit has been presented. The bracketry and installation methods disclosed herein substantially reduce the complexity and cost of performing a retrofit installation of a heavy ceiling fan or lighting fixture.

[0135] While the present invention has been described with regards to particular embodiments, it is recognized that additional variations of the present invention may be devised without departing from the inventive concept.