U.S. patent application number 12/420902 was filed with the patent office on 2010-10-14 for extended short span tee for drywall ceiling.
This patent application is currently assigned to USG INTERIORS, INC.. Invention is credited to Peder Gulbrandsen, James J. Lehane, Muhammad Raheel.
Application Number | 20100257807 12/420902 |
Document ID | / |
Family ID | 42933218 |
Filed Date | 2010-10-14 |
United States Patent
Application |
20100257807 |
Kind Code |
A1 |
Raheel; Muhammad ; et
al. |
October 14, 2010 |
EXTENDED SHORT SPAN TEE FOR DRYWALL CEILING
Abstract
A short span flat drywall ceiling construction comprising a pair
of spaced parallel wall angles facing one another, the wall angles
each having a vertical leg secured to vertical support surfaces and
a horizontal leg cantilevered from its respective vertical leg
towards the other wall angle, a plurality of substantially
identical roll-formed sheet metal tees extending between the wall
angles and vertically supported thereby, each tee having a main
body formed of a single strip of sheet steel, the tee having a
horizontal single layer lower flange, a vertical double layer
central web disposed above the flange, and a bulb at the top of the
web centered on a plane of symmetry, a sheet metal U-shaped
reinforcement channel fitted on a central part of the length of the
tee such that it is in contact with at least the sidewalls of the
bulb.
Inventors: |
Raheel; Muhammad;
(Mundelein, IL) ; Gulbrandsen; Peder; (Aurora,
IL) ; Lehane; James J.; (McHenry, IL) |
Correspondence
Address: |
PEARNE & GORDON LLP
1801 EAST 9TH STREET, SUITE 1200
CLEVELAND
OH
44114-3108
US
|
Assignee: |
USG INTERIORS, INC.
Chicago
IL
|
Family ID: |
42933218 |
Appl. No.: |
12/420902 |
Filed: |
April 9, 2009 |
Current U.S.
Class: |
52/506.07 |
Current CPC
Class: |
E04B 9/245 20130101;
E04B 9/068 20130101 |
Class at
Publication: |
52/506.07 |
International
Class: |
E04B 9/22 20060101
E04B009/22 |
Claims
1. A short span flat drywall ceiling construction comprising a pair
of spaced parallel wall angles facing one another, the wall angles
each having a vertical leg secured to vertical support surfaces and
a horizontal leg cantilevered from its respective vertical leg
towards the other wall angle, a plurality of substantially
identical roll-formed sheet metal tees extending between the wall
angles and vertically supported thereby, each tee having a main
body formed of a single strip of sheet steel, the tee having a
horizontal single layer lower flange, a vertical double layer
central web disposed above the flange, and a bulb at the top of the
web centered on a plane of symmetry, the bulb having a pair of
opposed generally vertical walls each spaced from the plane of
symmetry, a top bridging a space between the vertical walls and a
bottom that merges with the double layer of the web, a sheet of
drywall secured against lower faces of the tees with screws driven
through the drywall into the flanges of the tees, a sheet metal
U-shaped reinforcing channel fitted on a central part of the length
of the tee such that it is in contact with at least the sidewalls
of the bulb, the nominal height of the main body of the tees being
between about 11/2'' to about 15/8'', the length of the tees being
between preferably about 7' to preferably between about 81/2' to
about 9' long.
2. A ceiling construction as set forth in claim 1, wherein the
reinforcing channel is on the inside of the bulb and runs the full
length of the tee.
3. A ceiling construction as set forth in claim 1, wherein said
reinforcing channel is fixed to the outside of the bulb.
4. A ceiling construction as set forth in claim 3, wherein said
channel has a central rib extending above the bulb.
5. A ceiling construction as set forth in claim 4, wherein the bulb
has a vertical height, the central web of the reinforcing channel
extends above the bulb a distance at least half the height of the
bulb.
6. A ceiling construction as set forth in claim 1, wherein the tees
are spaced from one another a nominal distance of 16'' or 24'' or
metric equivalent.
7. An extended short span tee for constructing flat drywall
ceilings, the tee being roll-formed from two strips of steel sheet
and being symmetrical about a central vertical plane, a first of
said strips forming a single layer horizontal lower flange, a
double wall central vertical web and a hollow upper reinforcing
bulb, the reinforcing bulb being generally rectangular in
cross-section with generally vertical sidewalls, the second strip
being formed into an inverted U-shaped channel with a pair of
vertical sidewalls and a horizontal web, the channel sidewalls
being proportioned to abut the sidewalls of the reinforcing bulb,
the first strip of the tee having a length of between about 7' and
about 9' or metric equivalent.
Description
BACKGROUND OF THE INVENTION
[0001] The invention relates to building construction and, in
particular, to short span flat drywall ceiling construction.
PRIOR ART
[0002] A type of ceiling construction found in commercial buildings
involves the use of horizontally spaced inverted metal tees
suspended by wires from overlying structure. Sheets of drywall are
fastened by screws to these metal tees and then are taped and
otherwise finished. Building areas such as corridors, stairwells,
landings, and small rooms found in apartments, condominiums,
hotels, motels, dormitories, and the like are commonly finished
with flat drywall ceilings. These building areas are typically
relatively narrow and, therefore, involve a relatively short span
from wall-to-wall. In many instances, the space or plenum above the
ceiling, especially in corridors and hallways, is occupied by duct
work, conduit, and mechanical equipment. The presence of this and
like equipment frequently interferes with the installation of
suspension wires. As a result, additional layout planning,
tradesmen scheduling and, eventually, more labor, is incurred.
Frequently, unforeseen physical interference problems add to the
cost of construction.
SUMMARY OF THE INVENTION
[0003] The invention involves an improved tee construction that can
advantageously be used for supporting flat drywall ceilings in
extended "short span" applications. The disclosed tee construction
is capable of supporting standard drywall sheets and satisfying
applicable building codes while avoiding the need for suspension
wires. The tees of the invention are sufficiently rigid to enable
them to be supported exclusively at their ends on conventional wall
angles. This rigidity avoids the labor of anchoring overhead
suspension wires and the problems associated with interference with
equipment in the space above the ceiling. The disclosed tees are
commercially made with mostly existing technology, tooling, and
material stock. Only a limited quantity of extra material is used
in the manufacture of the disclosed tee forms of the invention.
[0004] More specifically, standard drywall tees are effectively
rigidified by increasing their section modulus with a channel sized
to closely fit with the standard reinforcing bulb provided at the
top of the inverted standard drywall tee form. The resulting tee,
in accordance with the invention, is familiar in form and size. The
relatively low profile or height of the inventive tee affords full
utilization of the space above the ceiling for free placement of
utilities, duct work and like equipment without the need to leave
clearance for suspension wires or to improvise and fabricate custom
anchor points for the suspension wires. The freedom to use the full
space of the plenum and not be hindered by suspension wires or
supplemental brackets or supports is an important feature. This
freedom is in addition to the basic cost savings obtained by
eliminating the need for locating, installing, and tying off
suspension wires.
[0005] The disclosed tee construction of the invention retains the
benefit of a relatively light gauge tee body material and a single
wall flange thereby affording easy and reliable penetration by
self-drilling drywall screws.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an isometric schematic view of an extended short
span flat drywall ceiling;
[0007] FIG. 2 is a fragmentary isometric view of the ends of the
tees of the invention and their relation to a wall angle;
[0008] FIG. 3 is a diagrammatic illustration of the
height-to-length ratio of the tee of the invention;
[0009] FIG. 4 is a fragmentary cross-sectional view of a first
embodiment of the tee of the invention;
[0010] FIG. 5 is a fragmentary cross-sectional view of a second
embodiment of the tee of the invention; and
[0011] FIG. 6 is a fragmentary cross-sectional view of a third
embodiment of the tee of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] FIG. 1 illustrates a corridor, hallway or other building
area 10 characterized by a relatively short span ceiling structure
11 between opposing walls 12 and finished with a flat drywall
surface. The term "flat" means that the drywall sheets are
installed in a flat plane although their finished lower sides may
be textured as is customary. Only a fragmentary area of the drywall
13 of the ceiling structure 11 is shown to reveal the arrangement
of a plurality of tees 14 supporting the ceiling drywall.
[0013] The opposed walls 12 can be of any suitable construction. In
reference to FIG. 2, the illustrated walls 12 are constructed of
vertical sheet metal studs 16 on which are hung drywall sheets 17.
It will be seen that the opposite wall assemblies formed by the
studs 16 and drywall 17 serve as the vertical supports for the
ceiling structure 11.
[0014] The ceiling structure 11 comprises a wall angle 18 on each
of the opposed walls 12, support tees 14 extending between the wall
angles, and drywall sheets 13 screwed to the lower sides of the
tees. The wall angles 18 are conventional elements preferably
formed from knurled or dimpled sheet metal strips and are nominally
1'' high by 11/2'' wide or metric equivalents, and of, for example,
a nominal gauge of 0.020 inch thickness. The wall angles 18,
typically, are secured to the walls 12 with self-drilling drywall
screws 21 driven through the drywall sheets 17 into the studs
16.
[0015] FIG. 4 illustrates a first embodiment of a tee 26 in
cross-section. The tee has a main body 27 roll-formed of a single
strip of sheet metal. The strip is, for example, relatively light
gauge stock being about 0.018'' galvanized (G40) hot-dipped steel
(HDG). The form of the tee main body 27 is conventional. At the
lower side, the tee main body 27 includes a single layer horizontal
flange 28 comprising oppositely extending parts 29. Distal edges of
the flange parts 29 have hems 31 folded over their upper sides.
Adjacent and parallel to their distal edges, the flange parts 29
have small grooves 32 that serve to restrain screws from "skating"
laterally off of the lower face of the flange 28 when being screwed
into the flange. Additionally, the lower face of the flange 28 can
be knurled, as is known, to stabilize a screw tip and further
prevent it from skating across this lower flange face. At their
proximal edges, the flange parts 29 merge integrally with
respective layers 33 of a double layer or double wall vertical web
34. The web layers 33 are fixed together by a suitable fastening
process such as the stitching technique shown in U.S. Pat. No.
6,047,511, clinching as shown in U.S. Pat. No. 6,041,564, or by
welding, adhesives, or other known expedient. The web layers 33, at
their upper edge, merge integrally with a hollow reinforcing bulb
36. More specifically, the web layers 33 join lower sides 37 of the
bulb 36. In the illustrated example, the lower sides 37 of the bulb
36 are nearly horizontal, being nominally about 5 degrees off true
horizontal. The bulb 36 is generally rectangular in cross-sectional
shape. By way of example, the flange 28 from edge-to-edge can
extend nominally 11/2'' and the height of the tee main body 27 from
the bottom face of the flange 28 to the top face of the bulb can be
nominally 15/8'', or metric equivalents.
[0016] A roll-formed sheet steel inverted channel 41 is closely
fitted and assembled in the interior of the bulb 36. The material
of the channel 41 can be slightly heavier in gauge than the tee
main body 27. For example, the stock forming the channel 41 can be
a nominal minimum of 0.024'' thick. Ideally, a bight 42 of the
channel 41 abuts the upper wall of the bulb 36. The channel 41
ordinarily will run from end-to-end of the tee main body 27. The
channel 41 can be locked in the illustrated position by
appropriately punching or piercing the sidewalls, designated 43 of
the bulb 36 at spaced locations along the length of the main tee
body 27.
[0017] FIG. 3 diagrammatically illustrates the relative geometry of
the tee 26 formed by the main body 27 and the channel insert 41.
The height "H" of the tee main body 27 is nominally 15/8'' and the
length of the tee 26 will be between about 7' and about 81/2' to
about 9', for example. It has been projected that a length greater
than a dimension between about 9' to about 91/2' would require an
amount of additional channel stock which would make the disclosed
tee construction uneconomical. The tee 26 ordinarily obtains its
vertical support solely at its ends from reaction forces developed
by the wall angles 18. That is, the tees 26 are sufficiently rigid
to be devoid of any vertical support along the entire span between
the wall angles 18. This capability eliminates the labor and
materials attendant with hanging suspension wires from overhead
structures and leaves the full space above the tees 26 available
for building equipment. In FIG. 3, the length L denotes the length
of the tees.
[0018] FIG. 4 shows the relationship of a sheet 13 of drywall and a
typical tee. By way of example, the drywall sheet 13 is illustrated
as 5/8'' thick; where appropriate 1/2'' thick drywall can be
similarly used. As is customary, a plurality of self-drilling
drywall screws 21 secure the drywall sheet 13 to the bottom of the
tee flange 28. The single wall light gauge character of the tee
main body 27 is of great advantage over heavier gauges or
double-layer flanges because it is relatively easy to pierce this
stock with a common, commodity quality self-drilling drywall
screw.
[0019] FIG. 5 illustrates a second embodiment of a tee 46 in
cross-section. A tee main body can be identical to the tee main
body 27 disclosed in connection with FIGS. 1-4. In the tee 46 of
FIG. 5, an inverted channel 48 is fitted, cap-like, over the
reinforcing bulb 36. Channel 48 is preferably roll-formed from a
strip of sheet steel of a gauge somewhat heavier than the gauge of
the main tee body 27. The channel gauge can be nominally a minimum
of 0.024'', for example. The channel 48 includes a pair of sides 49
proportioned to closely abut the sides of the hollow reinforcing
bulb 36 and to extend vertically over a major portion of the
vertical height of the bulb. The channel 48 is rigidly fixed in
place on the main body by appropriate staking, piercing, riveting,
welding, or the like. The length of the channel 48 need not extend
the full length of the main tee body 27 and can, for example, be
half or more in length as the length of the tee main body and be
centered lengthwise over the tee main body.
[0020] FIG. 6 illustrates yet another embodiment of an extended
short span tee 51. The tee 51 utilizes the tee main body 27,
referenced in connection with FIGS. 1-5, and a unique inverted
ribbed channel 52. The channel 52, like the earlier described
channels 41, 48 is, ideally, a one-piece or integral roll-formed
sheet steel strip preferably of a nominal gauge heavier than that
of the tee main body 27 such that it has a nominal minimal
thickness of 0.024'', for example. The channel has vertical
depending legs 53, horizontal webs 54 and an upstanding double wall
central flange or rib 56. Preferably, the height of the rib above
the bulb 36 is at least one-half the height of the sidewalls 43 of
the bulb. The webs 54 bridge the distance between the legs 53 and
the rib 56. The channel 52 is shaped to cause the legs 53 to abut
the sides of the bulb 36. The legs 53 cover a substantial portion
of the height of the bulb sides. The channel 52, like the channel
41 of FIG. 5, need not extend along the full length of the tee main
body 27 and can be about half as long as the tee main body and be
centered on its length. The channel 52 is fixed in position in the
same manner as described in connection with the channel 41 of FIG.
5. The rib or flange 56 adds significantly to the rigidity of the
tee 51 in a vertical plane.
[0021] While the invention has been shown and described with
respect to particular embodiments thereof, this is for the purpose
of illustration rather than limitation, and other variations and
modifications of the specific embodiments herein shown and
described will be apparent to those skilled in the art all within
the intended spirit and scope of the invention. Accordingly, the
patent is not to be limited in scope and effect to the specific
embodiments herein shown and described nor in any other way that is
inconsistent with the extent to which the progress in the art has
been advanced by the invention.
* * * * *