WO2002001110A1

WO2002001110A1 - Ceiling fixture mounting assembly

Info

Publication number: WO2002001110A1
Application number: PCT/US2001/041140
Authority: WO
Inventors: Jimmy J. Jones; Dennis D. Davenport
Original assignee: Encon Electric Licensing, L.L.C.
Priority date: 2000-06-27
Filing date: 2001-06-26
Publication date: 2002-01-03
Also published as: AU2001273635A1

Abstract

The present invention relates to useful ceiling fixture mounting apparatus and method of assembly that conceals various unsightly mechanical aspects of ceiling fixtures from view. The apparatus of the present invention includes canopy mounting assemblies and components for ceiling fixtures that are designed to conceal otherwise unsightly gaps and unused holes so that the ceiling fixture has a more aesthetically pleasing appearance. This invention also relates to a method of assembly of the ceiling fixture mounting apparatus which allows for mounting on electrical junction boxes which are not level with the ceiling surface, mounting on ceilings having an angle, such as cathedral ceilings, and mounting on ceilings having an uneven surface without creating unsightly gaps between the canopy and the ceiling, and which further conceals unsightly unused holes in the canopy.

Description

CEILING FIXTURE MOUNTING ASSEMBLY

Field Of The Invention

The present invention relates generally to ceiling fixtures, and more particularly, to useful and aesthetic ceiling fixture mounting assemblies, components, and methods which conceal various unsightly mechanical aspects of ceiling fixtures from view. This invention also relates to a ceiling fixture mounting apparatus and method of assembly that allow for mounting on an electrical junction box which is not level with the ceiling surface, mounting on ceilings having an angle, such as cathedral ceilings, and mounting on ceilings having an uneven surface.

Background Of The Invention Ceiling fixtures such as electrical lights and ceiling fans are used extensively in modern homes. In particular, ceiling fans have enjoyed growing popularity as a means to provide lighting and increased air circulation. Ceiling fans are now so popular that competitiveness in the industry often depends upon the useful and aesthetic features of one ceiling fan versus another. For these reasons, ceiling fans are commonly designed with differing mounting assemblies, and with differing useful and aesthetically pleasing canopies which conceal the mounting assemblies and other mechanical components from view. However, most ceiling fixture mounting assemblies fail to cover common unappealing features. Specifically, typical assemblies leave unappealing gaps between the canopy and a non-level ceiling, such as a cathedral ceiling, or a ceiling having an uneven surface. Conventional ceiling fixture mounting assemblies are designed to be mechanically secured to an electrical junction box in the ceiling. However, electrical junction boxes are often improperly installed in a manner such that the junction box is not level with the ceiling surface. Since conventional ceiling fixture mounting brackets install onto the junction box, non-level installation of the junction box results in a non-level mounting bracket. Because conventional canopies are mounted directly to the mounting bracket using side screws, conventional canopies cannot adjust for a non-level mounting bracket, and will leave an unsightly gap at the ceiling.

In the particular case of ceiling fans, the down rod of the ceiling fan is configured to fit within a socket of the mounting bracket so as to be suspended therefrom. Typically, the socket of the mounting bracket allows for some angular movement of the down rod so that the ceiling fan can be mounted to a ceiling that is slanted or otherwise non-level. Conventional hanger brackets of this type have achieved widespread use within the ceiling fan industry. Unfortunately however, conventional canopies are limited in the degree of angular adjustment permitted without leaving unsightly gaps between the top of the canopy and the ceiling.

Increasingly, modern ceiling fan canopies commonly referred to as "dual-mount" or "combo" canopies, are being utilized. Such combination canopies can be alternatively used with conventional down rods to suspend a ceiling fan from the ceiling or used as a means for directly connecting the fan to the hanger bracket to be substantially flush with the ceiling. For ceiling fans, this alternative combination is commonly achieved by means of a plurality of holes formed in the lowermost peripheral rim of the canopy. These lower canopy mounting holes allow the canopy to be directly connected to the upper surface of the motor housing of the ceiling fan by means of machine screws. The motor housing can then be connected directly to the hanger bracket. However, in such a combo canopy, it is noted that the lower canopy mounting holes present an unsightly appearance when the canopy is used for conventional down rod applications. Therefore, there exists a continuing need in the ceiling fan industry for useful ways to conceal holes of such conventional canopies so that a more aesthetically pleasing appearance is presented in downrod applications. Accordingly, it is an object of this invention to provide an improvement which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of the ceiling fixture art.

The foregoing outlines some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention and the detailed description of the preferred embodiments in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.

Summary of the Invention

The present invention is directed to an apparatus and method that solves the long felt need for creating a more useful and aesthetically appealing ceiling fixture mounting assembly. The present invention includes a variety of adjustable useful and aesthetic components for ceiling fixture mounting assemblies that are designed to conceal otherwise unsightly gaps and holes so that the ceiling fixture can be easily assembled to create a more aesthetically pleasing appearance.

Another object of the present invention is to provide a ceiling fixture canopy assembly that allows mounting of the ceiling fixture to a non-level ceiling such as a cathedral ceiling, an uneven electrical junction box, and a ceiling having an uneven surface, without creating an unsightly gap between the top of the canopy and the ceiling.

Another object of the present invention is to provide a side cover useful for concealing any unused holes in the upper rim of a canopy, thereby presenting a more aesthetically pleasing canopy appearance in downrod applications. Another object of this invention is to provide a lower canopy hole cover that conceals unused mounting holes in the lower peripheral rim of a combo canopy that would otherwise remain visible when the ceiling fixture is installed in a downrod application. One useful and aesthetic component of the invention consists of one or more side covers which cover any unused upper canopy mounting holes when the fixture is mounted downrod. Preferably, the side covers are made from plastic or another flexible material, and include two protruding tabs of slightly greater diameter than the mounting holes in the upper rim of the canopy. In one embodiment, the side covers are applied to a canopy prior to installation of the ceiling fixture downrod from a non-level or uneven ceiling. Protruding tabs on the side cover are placed into corresponding unused upper canopy mounting holes. The outer surface of the side cover is pressed until the tabs snap into the mounting holes, thereby eliminating the unsightly unused holes.

Another useful and aesthetic feature component of the invention is a lower canopy cover having a design that conceals the otherwise visible holes in the lowermost peripheral rim of a conventional combination canopy designed for dual mounting of the ceiling fixture via a down rod or directly to the hanger bracket.

In one preferred embodiment, the lower canopy cover includes an annular flat ring with two holes through the flat ring surface. The holes are positioned diametrically opposite one another. Once installed, the lower canopy cover conceals the otherwise visible holes in the base of the canopy and, at least partially, the central opening of the canopy.

In one aspect of the invention, the lower canopy cover is secured by use of threaded thumb screws which are inserted through holes in the lower canopy cover and corresponding lower canopy mounting holes. The thumbscrews are captured by threaded holes in the mounting bracket. In yet another aspect of the invention, the holes in the lower canopy cover are key-shaped to allow rotational locking of the canopy cover over the thumbscrew heads.

In another aspect of the invention, the canopy cover is secured by placing knurled nuts on the ends of threaded rods which protrude from the mounting bracket, through corresponding lower canopy mounting holes, and through corresponding lower canopy cover holes. The knurled nuts are then tightened until the upper rim of the canopy makes contact with the ceiling surface. Brief Description Of The Drawings

For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown. Figure 1 illustrates an exploded view of a ceiling fan mounting assembly according to one embodiment of the present invention which uses thumbscrews to adjustably connect the canopy components to the mounting bracket;

Figure 2 illustrates an exploded view of a ceiling fan mounting assembly according to another embodiment of the present invention which uses threaded rods and knurled nuts to adjustably connect the canopy components to the mounting bracket;

Figures 3A through 3C illustrate a side cover for covering upper canopy mounting holes according to one embodiment of the present invention. Figures 4A and 4B illustrate a mounting bracket according to one embodiment of the present invention.

Figure 5 illustrates a lower canopy cover bracket according to one embodiment of the present invention. Figures 6A and 6B illustrate a top view of a canopy bracket according to one embodiment of the present invention.

Detailed Description Of The Invention

Referring now to the drawings, wherein like numerals indicate like elements, there is shown in FIG. 1 an illustration of a ceiling fan mounting assembly 10. The assembly 10 includes a plurality of side covers 12 which cover a plurality of upper canopy mounting holes 14. Each protruding tab 13 of a side canopy cover 12 is inserted into a corresponding upper canopy mounting hole 14. The assembly also includes a plurality of threaded thumbscrews 16 connecting a mounting bracket 18, a canopy 20, and a lower canopy cover 22. The threaded end of one thumbscrew 16 is inserted into a threaded hole 28 (as shown in FIG. 4A) in the protruding socket portion 26. The opposite end of the thumbscrew is then threaded through a corresponding lower canopy mounting hole 32, and through a corresponding hole 34 in the lower canopy cover 22.

Each thumbscrew 16 is then individually tightened until the upper rim of the canopy 30 contacts the ceiling surface. In another aspect of the invention, the holes 34 in the lower canopy cover 22 are key-shaped to allow rotational locking of the canopy cover over the heads of the thumbscrews 16.

FIG. 2 illustrates a second embodiment of the present invention, where the ceiling fan mounting assembly 10 includes a plurality of side covers 12 which cover a plurality of upper canopy mounting holes 14. The assembly 10 also includes a plurality of threaded rods 15 connecting a mounting bracket 18, canopy 20, and lower canopy cover 22. A threaded rod 15 is inserted into each threaded hole 28 in the protruding socket portion 26 of the mounting bracket 18. The threaded rod 15 is inserted through a corresponding lower canopy mounting hole 32, and through a corresponding hole 34 in the lower canopy cover. A fastener such as a knurled nut 36 is then placed on the protruding lower end of the threaded rod 15 and adjustably tightened until the upper rim of the canopy 30 contacts the ceiling surface. FIG. 3 illustrates a preferred embodiment of side cover 12 of the present invention, where the side cover 12 includes two protruding tabs 13, wherein the diameter of each tab is slightly larger than the diameter of each corresponding upper canopy mounting hole 14.

FIG. 4 illustrates a preferred embodiment of the mounting bracket 18 of the present invention. The mounting bracket includes of a base portion 24 capable of mounting to a ceiling surface or electrical junction box, a protruding socket portion 26 capable of receiving a downrod 27. The socket portion 26 contains a plurality of diametrically opposed threaded holes 28 for receiving a threaded rod 15 or thumbscrew 16. FIG. 5 illustrates a preferred embodiment of a lower canopy cover

22 having a plurality of holes 34 for receiving an adjustable connector that is used to connect the lower canopy cover 22 to the canopy 20.

FIG. 6 illustrates a preferred embodiment of a combination canopy 20 having a plurality of upper canopy mounting holes 14 and lower canopy mounting holes 32. The combination canopy 20 is directly connected to the mounting bracket 18 and the lower canopy cover 22 and conceals down rod 27 and mounting bracket 18 as well as the fixture's wiring (not shown) from view.

These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it will be recognized by those skilled in the art of ceiling fixtures that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. It should therefore be understood that this invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the invention as set forth in the claims.

Claims

ClaimsWhat is claimed is:

1. A ceiling fixture mounting assembly, comprising: a mounting bracket having at least one adjustable connector; a canopy having a plurality of openings for receiving the adjustable connector; and a canopy cover for receiving the adjustable connector and covering a plurality of openings in the canopy.

2. The assembly of claim 1, further comprising a side cover for covering at least one opening in the canopy.

3. The assembly of claim 1 , further comprising a side cover for covering a plurality of openings in the canopy.

4. A ceiling fixture mounting assembly, comprising: a mounting bracket having a protruding socket portion containing a plurality of threaded holes; a down rod for suspending a ceiling fixture from the mounting bracket; a canopy having an upper rim forming a central opening, the upper rim having an inner diameter larger than the mounting bracket, and a plurality of upper canopy mounting holes about the upper rim; the canopy further having a lower rim forming a central opening slightly larger than the down rod, said lower rim having a plurality of mounting holes; a lower canopy cover having a plurality of holes which correspond to the mounting holes in the lower rim of the canopy; an adjustable connector for the mounting bracket, canopy, and lower canopy cover; and a side cover for covering unused upper canopy mounting holes.

5. A ceiling fixture mounting assembly as in claim 4, wherein the adjustable connector includes a plurality of thumbscrews, each thumbscrew having a threaded end and a head on the opposite end, the threaded end of each thumbscrew adjustably inserted into the threaded holes of the socket portion and the head end protruding from said mounting bracket through mounting holes in the canopy and corresponding holes in the lower canopy cover.

6. A ceiling fixture mounting assembly as in claim 4, wherein the adjustable connector comprises a plurality of threaded rods and fasteners, the threaded rods having one end adjustably inserted into said threaded holes of said socket portion, and the other end protruding from said mounting bracket through mounting holes in said canopy and corresponding holes in said canopy cover which are adjustably secured by fasteners.

7. A ceiling fixture mounting assembly as in claim 4, wherein the side cover comprises a backing portion with a plurality of protruding tabs which correspond to a plurality of upper canopy mounting holes.

8. A ceiling fixture mounting assembly as in claim 4, wherein the ceiling fixture is a ceiling fan.

9. A method for adjustably mounting a ceiling fixture comprising the steps of: attaching a mounting bracket to the ceiling or a ceiling-mounted electrical junction box; hanging a downrod from a protruding socket portion of the mounting bracket; inserting a threaded thumbscrew into each of a plurality of corresponding holes in the mounting bracket; wiring the ceiling fixture; lifting a canopy and guiding the downrod through a central opening hole in the canopy; guiding the protruding head of each thumbscrew through a corresponding lower canopy mounting hole; guiding the protruding head of each thumbscrew through a corresponding hole in a lower canopy cover; and tightening each thumbscrew until the upper rim of the canopy contacts the ceiling surface.

10. A method for adjustably mounting a ceiling fixture comprising the steps of: attaching a mounting bracket to the ceiling or a ceiling-mounted electrical junction box; hanging a downrod from a protruding socket portion of the mounting bracket; adjustably inserting a threaded rod into each of a plurality of holes in the mounting bracket; wiring the ceiling fixture; lifting a canopy and guiding the downrod through a central opening in the canopy; guiding the opposite protruding end of each threaded rod through a corresponding lower canopy mounting hole; guiding the protruding end of each threaded rod through a corresponding hole in a lower canopy cover; and adjustably threading a knurled nut onto said opposite end of each threaded rod.

11. A method for providing a covering for unused openings in a ceiling fixture canopy comprising the steps of: inserting the protruding tabs of a side cover into unused canopy mounting openings; and pressing the outer surface of the side cover until the tabs snap into the unused canopy mounting openings.