U.S. patent application number 13/960068 was filed with the patent office on 2015-02-12 for channel cross member.
This patent application is currently assigned to USG Interiors, LLC. The applicant listed for this patent is USG Interiors, LLC. Invention is credited to Peder J. Gulbrandsen, James J. Lehane, JR., Mark R. Paulsen, Abraham M. Underkofler.
Application Number | 20150040495 13/960068 |
Document ID | / |
Family ID | 52447383 |
Filed Date | 2015-02-12 |
United States Patent
Application |
20150040495 |
Kind Code |
A1 |
Lehane, JR.; James J. ; et
al. |
February 12, 2015 |
CHANNEL CROSS MEMBER
Abstract
A short cross member for a narrow utility channel formed of
malleable sheet metal and having a vertical double ply web and a
horizontal flange symmetrically disposed on both sides of a lower
edge of the web, integral end connectors formed on each end of the
cross member from sheet material contiguous with the web, the
integral end connectors being arranged to support the flange in
coplanar relation with flanges of the channel, the end connectors
and the web being weakened at a predetermined vertical line whereby
the cross member can be assembled in a narrow channel by bending at
the associated line of weakness to shorten the effective overall
length of the cross member.
Inventors: |
Lehane, JR.; James J.;
(McHenry, IL) ; Gulbrandsen; Peder J.; (Aurora,
IL) ; Paulsen; Mark R.; (Waukegan, IL) ;
Underkofler; Abraham M.; (Waukegan, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
USG Interiors, LLC |
Chicago |
IL |
US |
|
|
Assignee: |
USG Interiors, LLC
Chicago
IL
|
Family ID: |
52447383 |
Appl. No.: |
13/960068 |
Filed: |
August 6, 2013 |
Current U.S.
Class: |
52/220.6 ;
52/506.07; 52/745.06 |
Current CPC
Class: |
E04B 9/068 20130101;
E04B 9/18 20130101; E04B 9/122 20130101 |
Class at
Publication: |
52/220.6 ;
52/506.07; 52/745.06 |
International
Class: |
E04B 9/12 20060101
E04B009/12; E04B 9/14 20060101 E04B009/14 |
Claims
1. A short cross member for a narrow utility channel constructed of
main runners in a suspended ceiling grid, the cross member being
formed of malleable sheet metal and having a vertical double ply
web and a horizontal flange symmetrically disposed on both sides of
a lower edge of the web, integral end connectors formed on each end
of the cross member from sheet material contiguous with the web,
said web and integral end connector being formed as two plies, the
integral end connectors being arranged to support the flange in
coplanar relation with flanges of the channel main runners when the
integral end connectors are received in cross runner slots in the
main runners, the sheet material joining the integral end
connectors and the web being weakened at predetermined vertical
lines located at respective ends of the web whereby the cross
member can be assembled in a narrow channel by inserting a first of
said integral end connectors into a cross runner slot and the other
can be bent at the associated line of weakness at the web end to
shorten the effective overall length of the cross member and allow
the cross member to be initially diagonally positioned in the
channel and thereafter be rotated to a perpendicular position as
the other integral end connector is progressively inserted into a
cross runner slot opposite said first cross runner slot.
2. A cross member as set forth in claim 1, wherein said line of
weakness is formed by an aperture through the sheet material
disposed between the integral end connector and the web.
3. A cross member as set forth in claim 2, wherein said end
connectors are identical.
4. (canceled)
5. A cross member as set forth in claim 1, including a reinforcing
bulb along an upper edge of said web.
6. A cross member as set forth in claim 1, wherein said integral
end connector is cut with a rearwardly facing integral edge adapted
to couple with an end connector of a cross runner assembled in a
cross runner slot.
7. A narrow channel assembly for use in a suspended ceiling grid
comprising a pair of main runners held in parallel alignment on a
yoke disposed around the top and sides of the channel, the yoke
having tabs extending through opposed cross runner slots of the
main runners into the channel, a cross member extending across the
channel having a lower flange coplanar with a lower flange of the
main runner, the cross runner having stamped apertures aligned with
holes in said tabs, and fasteners assembled through said holes and
apertures to lock said channel, cross member and yoke together.
8. A narrow channel assembly for use in a suspended ceiling grid
comprising a pair of main runners each with a lower flange and with
aligned cross runner slots in webs above the flanges, a sheet metal
cross member, the cross member having a lower flange coplanar with
the flange of the main runners, the cross member having a double
ply web above its flange, an integral end connector at each end of
the cross member, each integral end connector being formed of two
plies and joined to the web, the integral end connectors being
disposed in opposite said cross runner slots in the main runners,
at least one of the integral end connectors having plies with
portions that are effectively entirely flat at the respective
receiving slot and are spread apart so that they lie in a plane
generally parallel to the main runners on a side of the main runner
opposite an interior of the channel to lock said cross runners in
place between said main runners.
9. A method of constructing a narrow utility channel for a
suspended ceiling comprising forming a channel with two main
runners having longitudinally spaced opposed cross runner slots,
assembling an inverted U-shaped yoke outside and above the space
formed by the main runners, the yoke having tabs assembled in a
pair of opposed cross runner slots, and assembling a cross member
in the channel, the cross member being provided with bendable
integral end connectors, inserting a first of the end connectors in
a first cross runner slot, bending a second of the end connectors
to foreshorten the cross runner, rotating the cross member from a
diagonal position to a perpendicular position while the bent
integral end connector is progressively inserted into a second
cross runner slot opposite said first cross runner slot.
Description
BACKGROUND OF THE INVENTION
[0001] The invention relates to suspended ceiling construction and,
in particular, to grid elements used with narrow utility channel
systems.
PRIOR ART
[0002] Narrow channel systems are available for housing or
otherwise locating various utility hardware in a conventional
rectangular ceiling grid and tile construction. The channels are
viewed as more harmonious or attractive than conventional
arrangements for locating lights, air diffusers and returns,
sprinklers and the like. Conventional arrangements, for example,
dedicate a full grid module space to a single utility and,
consequently, are more visually prominent than what is needed to
ordinarily house a particular utility. The subject narrow channel
systems, besides reducing the visibility of necessary utilities,
can add to the attractiveness of a ceiling.
[0003] It is known to construct narrow utility channels by aligning
a pair of conventional main runners or tees in close parallel
relation. A number of inverted U-shaped yokes, spaced along the
length of these main tees can be used to hold these main tees in
parallel channel-forming relation at the ceiling plane. The yokes
are located above the zone of the channel to provide space for
utility hardware. This type of construction presents a need for a
manner of trimming the ends of the hardware located in the channel
such as panels, lights, grilles or the like. Use of short cross
runners or tees with conventional end connectors for this purpose
has proven to be difficult if not impractical.
SUMMARY OF THE INVENTION
[0004] The invention provides a cross member for narrow suspended
ceiling channels useful for trimming the ends of typical components
assembled in the channels. The inventive cross members can be used
in different modes depending, inter alia, on whether a cross runner
slot of a main runner forming a side of the narrow channel is
occupied.
[0005] Cross runner slots of main runners or tees forming a narrow
channel can be occupied by a yoke that holds the tees in channel
forming relation, by an end connector of an intersecting grid cross
runner or tee, or can be unoccupied. The disclosed cross member can
be field modified to be connected to a tee supporting yoke at a
cross tee slot, or can be mated directly with an end connector of
an intersecting grid tee at a cross tee slot, or can be installed
and locked in an otherwise unoccupied cross tee slot.
[0006] The disclosed cross member is conveniently produced from
grid tee stock ordinarily used in the manufacture of standard tees.
Consequently, no special tooling or manufacturing procedures need
be used to produce the tee stock for the inventive cross members.
Lengths of the tee stock are cut into short pieces with a stamping
die. The stamping die simultaneously cuts a shaped second or
trailing end of one cross member as that piece is being completed
and a shaped first or leading end of a next succeeding cross member
piece to be formed. The shaped ends serve as integral end
connectors.
[0007] The cross member integral end connectors, which are
identical, have several features that can facilitate installation
and connection with various elements. The integral end connectors
can clip onto opposed standard end connectors of intersecting cross
tees. Alternatively, the integral end connectors are easily trimmed
to avoid interference with a web of a main tee when connected to a
yoke. The integral end connectors, additionally, have an aperture
located to facilitate a connection with a yoke or, alternatively,
enable the end to be temporarily bent to facilitate assembly into a
narrow channel. The integral end connectors are double plies of
malleable sheet metal; the plies can be separated and folded
tightly against the web of a main tee to lock an end connector in
an otherwise unoccupied cross tee slot.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a channel cross member
constructed in accordance with the invention;
[0009] FIG. 2 is a fragmentary side view of an end of the cross
member;
[0010] FIG. 3 is a fragmentary perspective view of the cross member
assembled in a channel;
[0011] FIG. 4 is a diagrammatic plan view illustrating a manner of
assembling the cross member in a channel;
[0012] FIG. 5 is a fragmentary perspective view of an end of a
cross member attached to a main tee forming one side of a
channel;
[0013] FIG. 6 is a fragmentary side elevational view of a cross
member connected to an intersecting cross tee end connector;
[0014] FIG. 7 is a fragmentary perspective view of an assembly of
the cross member with a yoke used to construct a channel; and
[0015] FIG. 8 is a fragmentary side elevational view on an enlarged
scale of an end of a cross member joined to the yoke of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] FIG. 1 illustrates a cross member 10 embodying the invention
used in a narrow channel 11 depicted in FIG. 2. The channel 11 is
employed as a part of a suspended ceiling grid to support
utilities. The channel 11 is typically used with identical channels
in spaced parallel lines across a ceiling. The channel 11 affords a
popular ceiling treatment because it deploys utility hardware in a
package that is less obtrusive than hardware that occupies a full
grid module, which ordinarily is 2 foot by 2 foot or 2 foot by 4
foot (or industry metric equivalents thereof).
[0017] The channel 11 is formed by a pair of closely spaced
parallel main runners or tees 12 of conventional construction used
in a suspended ceiling grid. A center-to-center spacing of 4 inches
or 6 inches (with metric equivalents of 100 mm. and 150 mm.) of the
channel forming main tees 12 is standard in the industry. Channels
11 are normally arranged to extend transversely from wall-to-wall.
Space inside the channel 11 is used to house utility components
such as light fixtures, air diffusers, air returns, sprinkler heads
and the like. These devices are ordinarily of a length less than
the length of a channel and, therefore, require a trim member
across the width of a channel 11 to give the utility component a
finished appearance at the ceiling plane. The cross member 10 can
be used to conceal or trim the longitudinal ends of utility
components and any filler panels interposed between such
components. It is desirable that the cross members have the same
appearance as the elements forming the surrounding ceiling grid and
are aligned with such elements. Use of special short length grid
tees with conventional separately formed end connectors for channel
cross members has been found to be prohibitively expensive and such
tees are difficult if not impossible to install without damage
after a channel 11 has been erected in a grid system.
[0018] The cross member 10 of the invention is preferably cut from
a length of the grid stock ordinarily used to produce 2 or 4 foot
(or metric equivalent) cross tees. The stock is roll formed sheet
metal. A main body of the tee stock comprises an upper hollow
reinforcing bulb 16, a double ply web 17, and lower opposed flange
elements 18 all formed from a single metal strip. A flange cap 19
covering the opposed flange elements 18 is formed of a separate
sheet metal strip. The strips are held in assembled relation by
longitudinal hems 21 of the flange cap 19 folded over longitudinal
edges of the flange elements 18. The flange elements 18 and flange
cap 19 form a lower flange 22 of the tee stock. The cross member 10
departs from current industry cross tee construction using separate
end connectors. The ends of the inventive cross member 10 are die
cut with integral end connectors or tongues 26 formed from areas of
the double ply web 17.
[0019] Each longitudinal end edge 27 of the flange 22 of a cross
member 10 lies in the plane of the flange. The integral end
connector 26 has a profile with upper and lower edges 28, 29
configured to be received in a standard cross tee slot 31 of a main
tee 12 with the flange 22 of the cross member 10 coplanar with a
main tee flange 32 and the flange end edge 27 abutting the
longitudinal edge of the main tee flange.
[0020] Referring in particular to FIG. 2, the integral end
connector 26 is lanced to one side, above the plane of the drawing
of FIG. 2, to create an internal rearwardly facing edge 36 and a
pocket 37 behind the edge in the area vacated by the lanced
material. As indicated in FIG. 1, the integral end connectors 26 on
the ends of the cross member 10 are identical. Rearward of the
pocket 37 at a predetermined location relative to the edge 36 an
oblong hole or vertical slot 38 is punched through the plies of the
integral end connector 26. The location of the flange end edge 27
relative to the integral end connector 26 depends on the width of
the main tee flange 32. Normally, the width of the cross member
flange 22 will be the same as the width of the main tee flange
32.
[0021] The main tees or runners 12 forming the channel 11 have
their cross tee slots 31 in alignment. In the present embodiment,
the cross tee slot 31 is of the type disclosed in U.S. Pat. Nos.
5,517,796 and 5,761,868. As will be discussed, the cross members 10
can be assembled in a pair of opposed slots 31 either or both being
empty or occupied by an end connector of an intersecting cross tee
45.
[0022] FIG. 3 illustrates the cross member 10 with its integral end
connectors 26 disposed in a pair of cross tee slots 31 of the main
tees 12 forming the channel 11. The proportions illustrated are
that of a 4 inch channel. When the cross member 10 is properly
assembled in the channel 11, both end edges 27 of its flange 22
butt against respective longitudinal edges of the main tee flanges
32. The cross member 10 in this position can produce a finished
look to the end of a utility device or panel disposed in the
channel 11.
[0023] The cross member 10 can be located at a cross tee slot 31 in
which an end connector 40 of an intersecting cross tee 45 is
received. Visually, this produces an uninterrupted line across the
channel 11 when the suspended ceiling grid is viewed from
below.
[0024] The integral end connector 26 is arranged to mate with the
type of cross tee end connector 40 disclosed, for example, in the
aforementioned U.S. Patents. A vertical strap 41 exists between a
lead edge 42 of the integral end connector 26 and the lance edge
36. The strap 41 is arranged to fit between a pair of opposed
projections 43, 44 of the end connector 40 of an intersecting cross
tee 45 (FIG. 6) and the forward projection 43 is received in the
pocket 37 of the integral end connector 37. There results a
positive connection between the integral end connector 26 and cross
tee end connector 40.
[0025] Normally the channel 11 is constructed before the cross
members 10 are installed. Consequently, the center-to-center
distance between the main runners 12 of the channel 11 is fixed.
The inventive cross member 10 facilitates its assembly into an
established channel 11. With reference to FIG. 4, one integral end
connector 26 of a cross member 10 is bent at a vertical line
through the oblong vertical hole 38. The existence of the hole or
slot 38 weakens the juncture between the integral end connector 26
and the cross member 17 so that the hole determines a bend or fold
line. FIG. 4 diagrammatically illustrates the assembly of a cross
member 10 into opposing slots 31 of the main tees 12. With the
cross member 10 diagonally oriented to the tees 12, an unbent
integral end connector 26 is inserted in a first one of the slots
31. The opposite integral end connector 26 is bent at the hole 38
out of plane of the cross member web 17 in a direction towards the
slot 31 into which it is to be installed. The bent integral end
connector 26 is caused to enter the intended slot 31 and as the
cross member 10 is moved into a final perpendicular position, the
bent integral end connector is fully received in the respective
slot. If an end connector 40 of an intersecting cross tee 45 exists
in a slot 31, the cross tee end connector will help register the
integral end connector 26 with the slot. The intersecting cross tee
end connector 40 is made of relatively stiff material, and will
tend to re-bend the integral end connector 26 into alignment with
its web 17.
[0026] When a cross member 10 is assembled in a cross tee slot 31
that is otherwise unoccupied, the two plies of the integral end
connector 26 can be manually pried apart with a flat blade
screwdriver or like tool. The plies, thereafter, can be bent flat
against the main tee web with a suitable tool, such as a small
hammer or mallet. This situation is illustrated in FIG. 5.
[0027] FIGS. 7 and 8 illustrate installation of a cross member 10
at cross tee slots 31 occupied by a yoke 51 used to maintain the
tees 12 in their channel-forming relative positions. U.S. patent
application Ser. No. 13/488,474, filed Jun. 5, 2012 discloses the
illustrated yoke 51. As suggested in FIG. 7, the yoke has tabs 52
that extend into a pair of opposed cross tee slots 31. As seen in
FIG. 8, a distal portion of the integral end connector 26 is
manually cut off by the technician installing the ceiling grid so
that it does not interfere with a web 54 of the associated main tee
12. The cross member 10 is positioned so that its flange 22 is
coplanar with the main tee flange 32. At this position, the yoke
tab 52 has a hole that registers with the oblong hole 38 of the
cross member 10. A rivet or other fastener 56 is assembled through
both the tab hole 53 and oblong hole 38 to lock these elements in
their relative position.
[0028] It should be evident that this disclosure is by way of
example and that various changes may be made by adding, modifying
or eliminating details without departing from the fair scope of the
teaching contained in this disclosure. The invention is therefore
not limited to particular details of this disclosure except to the
extent that the following claims are necessarily so limited.
* * * * *