Method of making and installing a ventillating air distribution channel
United States Patent 3911639
The supporting grid (e.g., main and cross inverted tees) of a suspended ceiling also completely supports ventilation air-distributing apparatus including the air supply duct. This apparatus comprises a lower air flow channel section formed of two extruded metal bars having vertical webs with hooks on the outside of the web defining ways into which the wings of a bracket project to hold the spaced bars in a channel assembly. Along the top of the web of each bar are two outwardly extending spaced arms which are used to hold the sides of a fiberglass air duct. With the exception of the brackets and optional air extractor, all component parts are brought together into subassemblies at the factory and shipped flat in stacks to the job where assembly of the duct-channel units is completed by the simple operation of folding the ducting and inserting the brackets at the ends of the channels to hold the unit together for mounting in the grid structure.
US Patent References:
Method of making knockdown shipping containers
Bell et al. - June 1951 - 2555530
Ceiling duct structure
LaVigne et al. - May 1964 - 3132579
Air distribution duct assembly
Lee et al. - April 1965 - 3177796
Ceiling construction
Dail - June 1965 - 3187661
Panel supporting structure
Kreuzer - March 1966 - 3241280
Method of making knockdown shipping containers
Bell et al. - June 1951 - 2555530
Ceiling duct structure
LaVigne et al. - May 1964 - 3132579
Air distribution duct assembly
Lee et al. - April 1965 - 3177796
Ceiling construction
Dail - June 1965 - 3187661
Panel supporting structure
Kreuzer - March 1966 - 3241280
Inventors:
Rachlin, Joel R. (Elm Grove, WI)
Neudek, Rudolph O. (Waukesha, WI)
Neudek, Rudolph O. (Waukesha, WI)
Application Number:
05/268512
Publication Date:
10/14/1975
Filing Date:
07/03/1972
View Patent Images:
Export Citation:
Primary Class:
Other Classes:
52/220.600, 52/781, 52/631, 454/303
International Classes:
E04B9/02; F24F13/02; F24F13/072; F24F13/06; E04B5/52; F24F13/06; F24F7/04
Field of Search:
52/495,741,745,631 98/4D,4DL 29/469 93/41.1
US Patent References:
| 3331305 | Duct attachment for attaching an air diffuser to an air duct | July 1967 | Oneson | |
| 3353472 | Dropped ceiling ventilator apparatus | November 1967 | Lee et al. | |
| 3353473 | Linear air diffusers | November 1967 | Oneson et al. | |
| 3397499 | Support system for a ceiling | August 1968 | Wart | |
| 3420142 | MACHINE FOR CUTTING FORMATIONS OF DIFFERENT SHAPES IN FIBERBOARD | January 1969 | Gale et al. | |
| 3577904 | SUSPENDED CEILING INTEGRATED AIR DISTRIBUTION SYSTEM | May 1971 | Lambert | |
| 3601032 | MOUNTING STRUCTURE FOR DUCTBOARD PLENUM CHAMBER ASSEMBLY | August 1971 | Lambert | |
| 3601033 | AIR DIFFUSER ASSEMBLY WITH INTEGRAL AIR RETURN | August 1971 | Lambert |
Primary Examiner:
Abbott, Frank L.
Assistant Examiner:
Braun, Leslie A.
Attorney, Agent or Firm:
Darbo, Robertson & Vandenburgh
Parent Case Data:
RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 10,508, filed Feb. 11, 1970 now U.S. Pat. No. 3,673,945, dated July 4, 1972. It relates particularly to a method of making and installing the duct-channel units.
Claims:
We claim
1. The method of making and installing an air-distributing duct-channel unit in the assembled supporting grid of spaced rails of a suspended ceiling which method comprises the steps of providing at a factory location a rectangular sheet of fiberglass ducting, providing two channel-forming bars each having conformations on a side thereof defining at least partially enclosed ways and structures for receiving and holding a side edge portion of said ducting, securing at the factory location one of said bars on each side of said ducting to form a unit subassembly, shipping said subassembly to the job location, forming a duct and attached channel at said job location by bending said ducting to bring said channel-forming bars into channel-forming position, inserting a bracket into said ways at each end of the pair of bars to hold the channel together and thus complete assembly of said air-distributing duct-channel unit, and thereafter installing the duct-channel unit so made in the supporting grid by seating the same upon rails of said grid for support thereby.
2. The method of claim 1 wherein a plurality of the subassemblies are stacked and fastened together and so shipped to the job location.
3. The method of claim 1 wherein a pair of spaced V grooves are cut into the top surface of the fiberglass ducting at the factory location to establish fold lines along which the ducting bends in forming the duct to provide a triangular duct and bring the channel-forming bars into the necessary position to form the channel.
4. The method of claim 1 wherein the bars have inner flanges which extend toward each other but leave an air gap between them in the assembled channel along the bottom portions thereof and a shutter adapted to vary the size of the gap is mounted upon each of said inner flanges at the factory location.
5. The method of claim 1 wherein a duct retainer adapted to more positively hold the side edge portions of the ducting in position relative to the bar in engagement therewith is inserted between the ducting and the bar structure at the factory location.
1. The method of making and installing an air-distributing duct-channel unit in the assembled supporting grid of spaced rails of a suspended ceiling which method comprises the steps of providing at a factory location a rectangular sheet of fiberglass ducting, providing two channel-forming bars each having conformations on a side thereof defining at least partially enclosed ways and structures for receiving and holding a side edge portion of said ducting, securing at the factory location one of said bars on each side of said ducting to form a unit subassembly, shipping said subassembly to the job location, forming a duct and attached channel at said job location by bending said ducting to bring said channel-forming bars into channel-forming position, inserting a bracket into said ways at each end of the pair of bars to hold the channel together and thus complete assembly of said air-distributing duct-channel unit, and thereafter installing the duct-channel unit so made in the supporting grid by seating the same upon rails of said grid for support thereby.
2. The method of claim 1 wherein a plurality of the subassemblies are stacked and fastened together and so shipped to the job location.
3. The method of claim 1 wherein a pair of spaced V grooves are cut into the top surface of the fiberglass ducting at the factory location to establish fold lines along which the ducting bends in forming the duct to provide a triangular duct and bring the channel-forming bars into the necessary position to form the channel.
4. The method of claim 1 wherein the bars have inner flanges which extend toward each other but leave an air gap between them in the assembled channel along the bottom portions thereof and a shutter adapted to vary the size of the gap is mounted upon each of said inner flanges at the factory location.
5. The method of claim 1 wherein a duct retainer adapted to more positively hold the side edge portions of the ducting in position relative to the bar in engagement therewith is inserted between the ducting and the bar structure at the factory location.
Description:
BACKGROUND AND SUMMARY OF THE INVENTION
Various forms of structures have been proposed and used for providing ventilating air distribution in connection with suspended ceilings. The systems in commercial use suffer from a common disadvantage; namely, they must be assembled (to a greater or lesser extent) at the ceiling level. This is difficult and awkward to do. Inevitably, it results in very high labor costs. At the very minimum they require the installation and attachment of wires, rods, or other supports to the air duct and distribution apparatus while the latter is otherwise being held in place. Great care and skill is needed to properly install the structures.
Also, in known systems, installation requires measuring and cutting and otherwise fitting of materials and parts in expensive custom manner. The bill of materials for a given job requires considerable figuring to arrange for a balanced and adequate supply of materials and parts. The systems and installation procedures are geared to now obsolete scales of building trade labor costs.
The principal object and advantage of the present invention is to provide a simplified air-distributing apparatus which may be completely assembled at a convenient working location (on a bench or even on the floor) and then merely lifted into place and deposited on the ceiling grid structure. Of paramount importance, expensive field labor is reduced to an almost absolute minimum by factory subassemblying the units so that only folding of the ducting along prepared fold lines and insertion of brackets at the ends of the channels is all that is needed on the job.
A further object is to provide ceiling air-distributing apparatus which is characterized by modular dimensioning and interacting components which makes possible efficient packaging, storage, handling and shipping, as well as installation.
A very real and important object and achievement of the invention is the saving of upwards of one-half of the field labor installation costs as compared with known contemporary systems.
Other objects and advantages will become apparent from the following description.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of portions of an installation utilizing one embodiment of the invention;
FIG. 2 is a sectional view illustrating the embodiment of FIG. 1 employed in a ceiling wherein the air-distributing apparatus is flush with the surface of the ceiling;
FIG. 3 is a perspective view of an example of a fiberglass duct section;
FIG. 4 is a perspective view of one of the brackets used for supporting the apparatus from grid tees;
FIG. 5 is a perspective view of a stack of subassemblies ready on the job for final assembly;
FIG. 6 is a perspective view of the stack showing the top unit assembled and ready for installation.
DESCRIPTION OF SPECIFIC EMBODIMENTS
The following disclosure is offered for public dissemination in return for the grant of a patent. Although it is detailed to ensure adequacy and aid understanding, this is not intended to prejudice that purpose of a patent which is to cover each new inventive concept therein no matter how others may later disguise it by variations in form or additions or further improvements. The claims at the end hereof are intended as the chief aid toward this purpose, as it is these that meet the requirement of pointing out the parts, improvements, or combinations in which the inventive concepts are found.
FIG. 1 illustrates the use of an embodiment with a ceiling system comprising conventional grid of longitudinal (main) tees 15 and cross-tees 16, with ceiling tiles 17. The tees conventionally have a bottom flange 18 on each side and a bulbous head 19. Any conventional means, such as wires (not shown), for supporting main tees 15 may be employed.
In this embodiment of the invention two bar members, generally 21 and 22, are employed. These bar members are formed from extruded metal, e.g., aluminum. They are identical and one has been turned end for end with respect to the other so that one forms a "left" and the other forms a "right." Describing, specifically, the bar on the left in FIG. 1, the section from which the bar member is formed comprises a vertical web 23, having at the lower end thereof an inwardly extending flange 24 and an outwardly extending flange 25. A longitudinal rib forms what may be termed a finger 26 extending upwardly in spaced relation to web 23. A hooked rib forms an upper finger 27. These two ribs, equally spaced from web 23, define a partially enclosed way for receiving the wings of the mounting brackets, as hereinafter described. An inwardly extending rib forms a shelf 28. Extending upwardly from the top of web 23 is an angular arm 29. A second arm 30 extends outwardly from web 23 in spaced, parallel relation to arm 29.
Adjacent the distal edge of the exterior bottom flange 25 is a downwardly extending support member 31 having a rib 32 along the bottom thereof.
To support the bar members 21 and 22 in proper relation to each other and form the air-distributing channel, and to mount the channel on the tees 15, a pair of brackets, generally 35, are employed (as best seen in FIGS. 1, 4 and 10). Bracket 35 is formed from sheet metal and includes a plate 36 which eventually lies alongside the vertical portion of the tee. Extending outwardly at right angles from plate 36 are a pair of wings 37 and 38. These wings are of a size to be received and securely retained in the ways defined by fingers 26 and 27 of the bars. When fully inserted in the ways, the web 23 of the bar members abuts the main plate 36 of the bracket.
Extending upwardly from the main plate 36 is a clip portion in the form of a bar 39 with three grippers 40, 41, 42 integral therewith. The grippers 41 and 42 are spaced apart by gaps equal to their individual lengths and are disposed eccentrically with respect to the center line of the bracket (as it exists midway between wings 37 and 38). The positioning is such that when the two brackets are applied to opposite sides of a supporting grid tee (see FIGS. 10 and 15) the grippers from the two sides interdigitate so that opposite wings of the two brackets on each side of the tee are in exact alignment. The lower portion 39a of the bar 39 fits under bulbous head 19 of the tee when the bracket is mounted thereon. This, in combination with the gripper 42 extending around the top of the head 19 and down partially over the far side, provides a secure gripping of the tee by the bracket.
A section of fiberglass ducting is used for the air supply duct. This is conventional ducting material which may be formed to the shape most convenient for the particular installation. Two folds 45 (FIG. 3) to form a triangular duct is usually the simplest. This triangular duct has a top 46 and two sides 47 and 48. The lower portions 47a and 48a of the two sides are inserted into the two slots defined by the spaced arms 29 and 30 of the bars 21 and 22. To facilitate this, the upper portions of arms 29 are outwardly curved, as indicated at 29a. The upper portion of arm 30 has an inwardly extending taper 30a extending to a step 30b. A duct retainer, generally 49, is applied to the sides of the duct before the latter is put into place. This retainer comprises a length of sheet metal having a bottom flange 50, a side 51 formed with an outwardly projecting detent 52, inwardly projecting prongs 53 and an upper release lever 54. These duct retainers 49 are applied to the edges of the duct with the prongs 53 being pressed securely into the fiberglass duct material. As the duct with its retainers then is inserted between the arms 29 and 30, the resilient fiberglass material being somewhat compressed in the process, the detent 52 ultimately snaps into place behind step 30b so as to securely lock the fiberglass duct to the bar members 21 and 22, the joint being self sealing against air leakage. Inward pressure on release lever 54 will disengage detent 52 from step 30b and permit removal of the duct from the channel.
Shutters, generally 55, are employed on inner flanges 24 to serve as dampers for the regulation of the air flow. These shutters are formed of continuous lengths of sheet metal bent into a U so as to have an upper plate 56 and a lower plate 57. These plates frictionally grip the inner flanges 24. The inner flanges may be formed with grooves 24a into which the detent end 56a can seat at a variety of positions. The end 57a is bent outwardly to form a handle to facilitate the manipulation of the damper from the room below the ceiling.
Between the bar members 21 and 22 is an air extractor, generally 58 (FIGS. 1 and 2). It comprises a plate 59, the longitudinal edges of which have been bent down to form flanges 60. Along the center portion a plurality of three-sided cuts were made with the metal within the cut areas being bent down to form a series of deflectors 61 and leaving openings 62 in the metal. The function of the extractor is to turn air downwardly when supplied for linear flow through the duct.
Along the under side is a cap or grille, generally 64, also preferably formed by metal extrusion. Along the under side, the cap has a center recess 65, into which the upper edge of a partition may be inserted if the area being ventilated is divided into rooms. A divider 66 extends upwardly at the center line of the cap and has an arrowhead ridge 67 along the top thereof. At each side of divider 66 the cap is provided with a plurality of openings 68. Along each side are upwardly extending support flanges 69 having hooks 70 (FIG. 1) along the inner sides thereof. These hooks 70 are for engaging the bulbous ridges 32 of support members 31 to hold the cap in place.
It is the common practice to position the longitudinal tees 15 on four foot centers. Accordingly, the bar members 21 and 22, the extractor 58, the duct sections 46-48, the duct retainers 49 and the shutters 55 would be cut into, and supplied in, 4 foot lengths (or just that amount short of 4 feet to allow for the thickness of the metal at each side of the center line of the tees). The caps may also be supplied in lengths exactly 4 feet long.
The air-distributing apparatus illustrated in FIG. 2 is identical with that already described. However, FIG. 2 illustrates the manner in which this system is employed in connection with a ceiling of the type wherein the ceiling tiles 76, instead of resting on the exposed flanges 77 of the tees, have slots 78 into which the flanges 77 extend. In this arrangement the tiles 76 that are to rest on flanges 25 of the air-distributing channels are notched out so that when the tile is in place it will be horizontal. The flanges 25 and the flanges 77 are at the same elevation whether the tiles and ceiling arrangement are of the type illustrated in FIG. 1 or the type illustrated in FIG. 2, but in the latter the supporting grid structure is hidden from view.
While the hardware for a single unit may be packaged together, assembled or unassembled, and so supplied to the job, maximum overall economy is achieved, in accordance with the present invention, by bringing together at the factory all channel-forming parts, with the single exception of brackets 35, and attaching these parts to the respective side edges of a sheet of ducting to form subassemblies that may be stacked flat and shipped to the job for minimum field assembly and installation operations. Such a stack 80 is illustrated in FIG. 5 resting upon a pallet 81. As is indicated by tapes 82, the stack may be fastened together and to a pallet at the factory for safe shipment to the job location.
As is shown, each flat subassembly 83 comprises a rectangular sheet 84 of fiberglass ducting having shallow V grooves 85 cut therein to establish fold lines and provide the necessary material clearance for folding the fiberglass sheet to form the triangular duct as illustrated in FIG. 3. The two bar members 21 and 22 carrying shutters 55 (not shown in FIG. 5) are mounted upon the edge portions of fiberglass ducting 84 with the aid of clips 51 (not shown in FIG. 5). Thus, all of the component parts for one-half of the eventual air-flow channel are mounted upon each of the sides of the eventual duct, each set of parts being identical to the other but so designed that when the fiberglass ducting 84 is folded, as indicated by arrows 86, to form the duct, the hardware subassemblies confront each other in position to form the channel and it is only necessary to slide a bracket 35 into the ways provided as hereinabove described as integral parts of the channel bar members 21 and 22. As is indicated in FIG. 6, a bracket is pushed into position at each end of the channel to thereby complete and fasten together the duct-channel unit.
After thus completing the assembly of the duct-channel unit, it is ready for mounting in the ceiling grid structure. If an air extractor 58 is to be used, it may be pushed into position upon ways 28 from one end of the channel unit after it is inverted since the extractor rests by gravity in the assembly. This may also be done, if preferred, after the unit has been installed in position in the grid structure. The air spreader cap 64 is attached to the channel after installation on the grid is complete.
As each unit is folded, fastened together by insertion of the brackets and removed for mounting in the ceiling grid, the next subassembly at the top of the stack is folded, bracketed and removed until all are assembled into duct-channel units and placed in position in the grid.
The very simple, single operation needed to completely assemble the duct-channel unit requires only a minute or two. Thus, expensive field labor is essentially limited to what can not possibly be done at the factory; namely, the mounting of the duct-channel units in position in the ceiling grid structure of the building in which the system is to be installed. At the same time, packaging and shipping expenses are minimal by reason of the flat form of the factory subassemblies which makes it possible to ship without packaging except for the brackets, the air-spreader caps and, if used, the air extractors.
It will be understood that while the triangular form of duct offers obvious advantages, the duct may be round or have other shape in cross section, the only requirement being that the two edges carrying the component subassemblies be brought into proximity with each other so that the channel is formed and fastened together by the brackets.
Various forms of structures have been proposed and used for providing ventilating air distribution in connection with suspended ceilings. The systems in commercial use suffer from a common disadvantage; namely, they must be assembled (to a greater or lesser extent) at the ceiling level. This is difficult and awkward to do. Inevitably, it results in very high labor costs. At the very minimum they require the installation and attachment of wires, rods, or other supports to the air duct and distribution apparatus while the latter is otherwise being held in place. Great care and skill is needed to properly install the structures.
Also, in known systems, installation requires measuring and cutting and otherwise fitting of materials and parts in expensive custom manner. The bill of materials for a given job requires considerable figuring to arrange for a balanced and adequate supply of materials and parts. The systems and installation procedures are geared to now obsolete scales of building trade labor costs.
The principal object and advantage of the present invention is to provide a simplified air-distributing apparatus which may be completely assembled at a convenient working location (on a bench or even on the floor) and then merely lifted into place and deposited on the ceiling grid structure. Of paramount importance, expensive field labor is reduced to an almost absolute minimum by factory subassemblying the units so that only folding of the ducting along prepared fold lines and insertion of brackets at the ends of the channels is all that is needed on the job.
A further object is to provide ceiling air-distributing apparatus which is characterized by modular dimensioning and interacting components which makes possible efficient packaging, storage, handling and shipping, as well as installation.
A very real and important object and achievement of the invention is the saving of upwards of one-half of the field labor installation costs as compared with known contemporary systems.
Other objects and advantages will become apparent from the following description.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of portions of an installation utilizing one embodiment of the invention;
FIG. 2 is a sectional view illustrating the embodiment of FIG. 1 employed in a ceiling wherein the air-distributing apparatus is flush with the surface of the ceiling;
FIG. 3 is a perspective view of an example of a fiberglass duct section;
FIG. 4 is a perspective view of one of the brackets used for supporting the apparatus from grid tees;
FIG. 5 is a perspective view of a stack of subassemblies ready on the job for final assembly;
FIG. 6 is a perspective view of the stack showing the top unit assembled and ready for installation.
DESCRIPTION OF SPECIFIC EMBODIMENTS
The following disclosure is offered for public dissemination in return for the grant of a patent. Although it is detailed to ensure adequacy and aid understanding, this is not intended to prejudice that purpose of a patent which is to cover each new inventive concept therein no matter how others may later disguise it by variations in form or additions or further improvements. The claims at the end hereof are intended as the chief aid toward this purpose, as it is these that meet the requirement of pointing out the parts, improvements, or combinations in which the inventive concepts are found.
FIG. 1 illustrates the use of an embodiment with a ceiling system comprising conventional grid of longitudinal (main) tees 15 and cross-tees 16, with ceiling tiles 17. The tees conventionally have a bottom flange 18 on each side and a bulbous head 19. Any conventional means, such as wires (not shown), for supporting main tees 15 may be employed.
In this embodiment of the invention two bar members, generally 21 and 22, are employed. These bar members are formed from extruded metal, e.g., aluminum. They are identical and one has been turned end for end with respect to the other so that one forms a "left" and the other forms a "right." Describing, specifically, the bar on the left in FIG. 1, the section from which the bar member is formed comprises a vertical web 23, having at the lower end thereof an inwardly extending flange 24 and an outwardly extending flange 25. A longitudinal rib forms what may be termed a finger 26 extending upwardly in spaced relation to web 23. A hooked rib forms an upper finger 27. These two ribs, equally spaced from web 23, define a partially enclosed way for receiving the wings of the mounting brackets, as hereinafter described. An inwardly extending rib forms a shelf 28. Extending upwardly from the top of web 23 is an angular arm 29. A second arm 30 extends outwardly from web 23 in spaced, parallel relation to arm 29.
Adjacent the distal edge of the exterior bottom flange 25 is a downwardly extending support member 31 having a rib 32 along the bottom thereof.
To support the bar members 21 and 22 in proper relation to each other and form the air-distributing channel, and to mount the channel on the tees 15, a pair of brackets, generally 35, are employed (as best seen in FIGS. 1, 4 and 10). Bracket 35 is formed from sheet metal and includes a plate 36 which eventually lies alongside the vertical portion of the tee. Extending outwardly at right angles from plate 36 are a pair of wings 37 and 38. These wings are of a size to be received and securely retained in the ways defined by fingers 26 and 27 of the bars. When fully inserted in the ways, the web 23 of the bar members abuts the main plate 36 of the bracket.
Extending upwardly from the main plate 36 is a clip portion in the form of a bar 39 with three grippers 40, 41, 42 integral therewith. The grippers 41 and 42 are spaced apart by gaps equal to their individual lengths and are disposed eccentrically with respect to the center line of the bracket (as it exists midway between wings 37 and 38). The positioning is such that when the two brackets are applied to opposite sides of a supporting grid tee (see FIGS. 10 and 15) the grippers from the two sides interdigitate so that opposite wings of the two brackets on each side of the tee are in exact alignment. The lower portion 39a of the bar 39 fits under bulbous head 19 of the tee when the bracket is mounted thereon. This, in combination with the gripper 42 extending around the top of the head 19 and down partially over the far side, provides a secure gripping of the tee by the bracket.
A section of fiberglass ducting is used for the air supply duct. This is conventional ducting material which may be formed to the shape most convenient for the particular installation. Two folds 45 (FIG. 3) to form a triangular duct is usually the simplest. This triangular duct has a top 46 and two sides 47 and 48. The lower portions 47a and 48a of the two sides are inserted into the two slots defined by the spaced arms 29 and 30 of the bars 21 and 22. To facilitate this, the upper portions of arms 29 are outwardly curved, as indicated at 29a. The upper portion of arm 30 has an inwardly extending taper 30a extending to a step 30b. A duct retainer, generally 49, is applied to the sides of the duct before the latter is put into place. This retainer comprises a length of sheet metal having a bottom flange 50, a side 51 formed with an outwardly projecting detent 52, inwardly projecting prongs 53 and an upper release lever 54. These duct retainers 49 are applied to the edges of the duct with the prongs 53 being pressed securely into the fiberglass duct material. As the duct with its retainers then is inserted between the arms 29 and 30, the resilient fiberglass material being somewhat compressed in the process, the detent 52 ultimately snaps into place behind step 30b so as to securely lock the fiberglass duct to the bar members 21 and 22, the joint being self sealing against air leakage. Inward pressure on release lever 54 will disengage detent 52 from step 30b and permit removal of the duct from the channel.
Shutters, generally 55, are employed on inner flanges 24 to serve as dampers for the regulation of the air flow. These shutters are formed of continuous lengths of sheet metal bent into a U so as to have an upper plate 56 and a lower plate 57. These plates frictionally grip the inner flanges 24. The inner flanges may be formed with grooves 24a into which the detent end 56a can seat at a variety of positions. The end 57a is bent outwardly to form a handle to facilitate the manipulation of the damper from the room below the ceiling.
Between the bar members 21 and 22 is an air extractor, generally 58 (FIGS. 1 and 2). It comprises a plate 59, the longitudinal edges of which have been bent down to form flanges 60. Along the center portion a plurality of three-sided cuts were made with the metal within the cut areas being bent down to form a series of deflectors 61 and leaving openings 62 in the metal. The function of the extractor is to turn air downwardly when supplied for linear flow through the duct.
Along the under side is a cap or grille, generally 64, also preferably formed by metal extrusion. Along the under side, the cap has a center recess 65, into which the upper edge of a partition may be inserted if the area being ventilated is divided into rooms. A divider 66 extends upwardly at the center line of the cap and has an arrowhead ridge 67 along the top thereof. At each side of divider 66 the cap is provided with a plurality of openings 68. Along each side are upwardly extending support flanges 69 having hooks 70 (FIG. 1) along the inner sides thereof. These hooks 70 are for engaging the bulbous ridges 32 of support members 31 to hold the cap in place.
It is the common practice to position the longitudinal tees 15 on four foot centers. Accordingly, the bar members 21 and 22, the extractor 58, the duct sections 46-48, the duct retainers 49 and the shutters 55 would be cut into, and supplied in, 4 foot lengths (or just that amount short of 4 feet to allow for the thickness of the metal at each side of the center line of the tees). The caps may also be supplied in lengths exactly 4 feet long.
The air-distributing apparatus illustrated in FIG. 2 is identical with that already described. However, FIG. 2 illustrates the manner in which this system is employed in connection with a ceiling of the type wherein the ceiling tiles 76, instead of resting on the exposed flanges 77 of the tees, have slots 78 into which the flanges 77 extend. In this arrangement the tiles 76 that are to rest on flanges 25 of the air-distributing channels are notched out so that when the tile is in place it will be horizontal. The flanges 25 and the flanges 77 are at the same elevation whether the tiles and ceiling arrangement are of the type illustrated in FIG. 1 or the type illustrated in FIG. 2, but in the latter the supporting grid structure is hidden from view.
While the hardware for a single unit may be packaged together, assembled or unassembled, and so supplied to the job, maximum overall economy is achieved, in accordance with the present invention, by bringing together at the factory all channel-forming parts, with the single exception of brackets 35, and attaching these parts to the respective side edges of a sheet of ducting to form subassemblies that may be stacked flat and shipped to the job for minimum field assembly and installation operations. Such a stack 80 is illustrated in FIG. 5 resting upon a pallet 81. As is indicated by tapes 82, the stack may be fastened together and to a pallet at the factory for safe shipment to the job location.
As is shown, each flat subassembly 83 comprises a rectangular sheet 84 of fiberglass ducting having shallow V grooves 85 cut therein to establish fold lines and provide the necessary material clearance for folding the fiberglass sheet to form the triangular duct as illustrated in FIG. 3. The two bar members 21 and 22 carrying shutters 55 (not shown in FIG. 5) are mounted upon the edge portions of fiberglass ducting 84 with the aid of clips 51 (not shown in FIG. 5). Thus, all of the component parts for one-half of the eventual air-flow channel are mounted upon each of the sides of the eventual duct, each set of parts being identical to the other but so designed that when the fiberglass ducting 84 is folded, as indicated by arrows 86, to form the duct, the hardware subassemblies confront each other in position to form the channel and it is only necessary to slide a bracket 35 into the ways provided as hereinabove described as integral parts of the channel bar members 21 and 22. As is indicated in FIG. 6, a bracket is pushed into position at each end of the channel to thereby complete and fasten together the duct-channel unit.
After thus completing the assembly of the duct-channel unit, it is ready for mounting in the ceiling grid structure. If an air extractor 58 is to be used, it may be pushed into position upon ways 28 from one end of the channel unit after it is inverted since the extractor rests by gravity in the assembly. This may also be done, if preferred, after the unit has been installed in position in the grid structure. The air spreader cap 64 is attached to the channel after installation on the grid is complete.
As each unit is folded, fastened together by insertion of the brackets and removed for mounting in the ceiling grid, the next subassembly at the top of the stack is folded, bracketed and removed until all are assembled into duct-channel units and placed in position in the grid.
The very simple, single operation needed to completely assemble the duct-channel unit requires only a minute or two. Thus, expensive field labor is essentially limited to what can not possibly be done at the factory; namely, the mounting of the duct-channel units in position in the ceiling grid structure of the building in which the system is to be installed. At the same time, packaging and shipping expenses are minimal by reason of the flat form of the factory subassemblies which makes it possible to ship without packaging except for the brackets, the air-spreader caps and, if used, the air extractors.
It will be understood that while the triangular form of duct offers obvious advantages, the duct may be round or have other shape in cross section, the only requirement being that the two edges carrying the component subassemblies be brought into proximity with each other so that the channel is formed and fastened together by the brackets.