Adjustable Hanger Assembly for Metal Bar Joists

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Solution Overview

Problem

Conventional methods for hanging ceiling fixtures from metal bar joists or beams, such as welding angle irons, are inflexible, cause structural damage, require skilled welders, and increase construction costs, especially when the desired location is between joists or beams.

Innovation Solution

An adjustable hanger assembly that bolts onto metal bar joists or beams, featuring clamps and fixture hanging assemblies with asymmetrical angles or channels that brace each other to increase load-bearing capacity, allowing for adjustable mounting of ceiling fixtures along the span between joists or beams.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If angle iron is welded to bar joists or beams to create a hanging point, then a fixture mounting location is provided, but the solution becomes inflexible and cannot be easily relocated if the desired location changes

Engineering Contradiction:

Improverelocatability of fixture mounting locationVSAvoiddifficulty of welding and installation

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The hanger assembly is divided into separate modular components: an adjustable hanger body that attaches to the bar joist, and a separate fixture mounting assembly. This segmentation allows the fixture to be relocated by detaching and reattaching the mounting assembly without affecting the permanent hanger installation, solving the inflexibility problem of welded angle iron.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hanger assembly incorporates adjustable mechanisms including telescoping rods with locking collars and rotating mounting plates. These dynamic features enable the fixture position to be adjusted along the bar joist span and oriented in different directions, providing the relocatability and adaptability that eliminates the need for permanent welding.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If angle iron is welded to bar joists or beams, then a fixture mounting location is created, but unintended structural damage may occur to the remaining length of the bar joists or beams

Engineering Contradiction:

Improvefixture mounting capabilityVSAvoidstructural damage to bar joists or beams

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The hanger assembly introduces a intermediary mounting system that attaches to the bar joist through clamps or brackets at strategic locations, rather than welding directly to the joist web. This intermediary approach distributes loads through the flanges and avoids concentrated welding heat that could compromise the structural integrity of the bar joist.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If angle iron is welded between bar joists or beams, then a spanning support is created, but the welding must be performed from awkward angles with limited space constraints

Engineering Contradiction:

Improvespanning support capabilityVSAvoidwelding accessibility and space constraints

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The hanger assembly separates the spanning support function (permanent hanger body attached to bar joists) from the fixture mounting function (adjustable mounting assembly). This allows the support structure to be installed in optimal locations while the fixture can be positioned anywhere along the span using the adjustable mounting mechanism, eliminating the need for awkward welding in limited spaces.

Inventive Principle:

Principle #1Segmentation

4Reliability

If skilled certified welders are used to weld angle iron to bar joists or beams, then a secure attachment is achieved, but construction costs increase

Engineering Contradiction:

Improveattachment securityVSAvoidconstruction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The hanger assembly replaces the welding process with mechanical attachment methods including high-strength bolts, threaded rods, and locking collars. These mechanical fasteners provide secure attachment comparable to welding but can be installed by general construction workers without specialized welding certification, thereby reducing labor costs while maintaining reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8776469B2Adjustable hanger assembly for use with metal bar joists and beams

Publication Date: 2014.07.15 MOREY DOUGLAS H

AI summary

An adjustable hanger assembly for hanging support rods or ceiling fixtures includes two adjacent spanning angles or channels having at least one clamp assembly at each end thereof and at least one fixture hanging assembly disposed between the ends of the spanning angles or channels. The clamp for use with joists utilizing angles includes legged and washer clamp plates, fastener, and fastening device. The clamp for use with beams utilizing angles includes alternate legged clamp plate, fastener hook, and fastening device. The fixture hanging assembly includes legged and washer fixture plate, hanger rod with threaded end, and fastening. Each legged clamp plates, alternate legged clamp plates, and legged fixture plates is adapted to ride horizontally along top of spanning angles or channels. The load bearing capacity of the angles or channels is increased by bracing these members against each other at clamp assembly and fixture hanging assembly locations.