U.S. patent application number 14/462716 was filed with the patent office on 2016-02-25 for free span ceiling grid system.
The applicant listed for this patent is USG Interiors, LLC. Invention is credited to Peder J. Gulbrandsen, Donald J. Leahy, James J. Lehane, Michael O'Donnell, Yelena Straight, Lee M. Tedesco, Abraham M. Underkofler, John M. Willi.
Application Number | 20160053488 14/462716 |
Document ID | / |
Family ID | 53879822 |
Filed Date | 2016-02-25 |
United States Patent
Application |
20160053488 |
Kind Code |
A1 |
Lehane; James J. ; et
al. |
February 25, 2016 |
FREE SPAN CEILING GRID SYSTEM
Abstract
Components for constructing a ceiling grid across a span free of
or with a limited number of suspension wires including main runners
with a relatively high moment of inertia secured at their ends with
brackets to wall moldings on opposing walls.
Inventors: |
Lehane; James J.; (McHenry,
IL) ; Tedesco; Lee M.; (Shorewood, IL) ;
Gulbrandsen; Peder J.; (Aurora, IL) ; Willi; John
M.; (Westlake, OH) ; Leahy; Donald J.; (North
Olmsted, OH) ; Underkofler; Abraham M.; (Waukegan,
IL) ; Straight; Yelena; (North Buffalo Grove, IL)
; O'Donnell; Michael; (Modesto, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
USG Interiors, LLC |
Chicago |
IL |
US |
|
|
Family ID: |
53879822 |
Appl. No.: |
14/462716 |
Filed: |
August 19, 2014 |
Current U.S.
Class: |
52/167.1 ;
52/506.05; 52/506.07; 52/705; 52/714 |
Current CPC
Class: |
E04B 9/008 20130101;
E04B 2009/186 20130101; E04B 9/16 20130101; E04B 9/34 20130101;
E04B 9/001 20130101; E04B 9/10 20130101; E04B 9/30 20130101; E04B
9/127 20130101; E04B 9/067 20130101; E04B 9/068 20130101 |
International
Class: |
E04B 9/06 20060101
E04B009/06; E04B 9/34 20060101 E04B009/34; E04B 9/10 20060101
E04B009/10; E04B 9/00 20060101 E04B009/00 |
Claims
1. A suspended ceiling grid comprising a plurality of parallel
regularly spaced main runners, each one of a pair of opposed
oppositely facing channels being disposed adjacent one end of said
main runners, said channels each having a vertical web and a
horizontal flange at top and bottom edges of the web, a bracket at
each end of each main runner, the bracket being attached to the
main runner with a first self-drilling screw and to the web of the
channel with a second self-drilling screw, each main runner
extending in one piece from one channel to the other channel and
being exclusively supported by the channels with sufficient support
capacity to permit the main runners to support a conventional
acoustical ceiling while being free of suspension wires or other
overlying support elements along the full length of the main
runners between said channels, each main runner having an upper
reinforcing bulb and a lower flange, the bracket having a main
runner engaging portion with upper and lower edges extending along
the portion, the lower edge being straight along its full flange
engaging length and fitted to the flange such that there is
essentially no ability of the bracket to rotate perceptively
relative to the main runner and otherwise allow the main runner to
droop perceptively below its originally installed position, the
flange at the top of the channel web serving to stiffen the channel
web to prevent the channel web from pulling away from the
respective wall due to a load imposed on the channel by the main
runners.
2. A suspended ceiling grid as set forth in claim 1, wherein said
main runners support acoustical panels and are about 8 feet or
greater in length.
3. (canceled)
4. (canceled)
5. A suspended ceiling grid as set forth in claim 1, wherein said
channel is roll formed sheet metal.
6. A suspended ceiling grid as set forth in claim 5, wherein said
upper and lower flanges have inturned hems at their distal
margins.
7. A suspended ceiling grid as set forth in claim 6, wherein said
brackets have tabs proportioned to lock into said channels between
said hems and said web.
8. A suspended ceiling grid as set forth in claim 7, wherein the
flanges of said channels are of different widths corresponding to
face widths of conventional grid runner face widths.
9. A suspended ceiling grid as set forth in claim 8, wherein said
bracket has a functional orientation and has multiple tabs of
different lengths at a lower edge.
10. A suspended ceiling grid comprising a plurality of parallel
regularly spaced main runners, each one of a pair of opposed
oppositely facing channels being disposed adjacent one end of said
main runners, said channels each having a vertical web and a
horizontal flange at top and bottom edges of the web, a bracket at
each end of each main runner, the bracket being attached to the
main runner and with a first self-drilling screw and to the web of
the channel with a second self-drilling screw, each main runner
extending in one piece from one channel to the other channel and
being exclusively supported by the channels with sufficient support
capacity to permit the main runners to support a conventional
acoustical ceiling while being free of suspension wires or other
overlying support elements along the full length of the main
runners between said channels, said channels being roll formed
sheet metal, said upper and lower flanges having inturned hems at
their distal margins, said brackets having tabs proportioned to
lock into said channels between said hems and said web, the flanges
of said channels being of different widths corresponding to face
widths of conventional grid runner face widths, said bracket having
a functional orientation and having multiple tabs of different
lengths at a lower edge, said multiple tabs including a lower tab
that is bendable from a generally horizontal orientation to a
generally vertical orientation to allow another tab of said
multiple tabs shorter than said bendable tab to engage a hem edge
of a narrow one of said flanges.
11. In combination, a metal grid runner, a generally L-shaped
bracket with first and second perpendicular legs, the first leg
being arranged to be attached to a side of the grid runner at an
end thereof, the second leg having upper and lower tabs for
engaging inturned hems at flanges of a sheet metal C-shaped channel
when inserted into the channel, the lower tabs having two different
generally horizontal lengths whereby the bracket can be retained by
a shorter tab when the channel has a lower shorter flange and by a
longer tab when the channel has a lower longer flange.
12. The combination as set forth in claim 11, wherein the first leg
has a vertical height greater than a standard grid tee height.
13. A sheet metal bracket for supporting a grid runner from a
channel shaped wall molding, the bracket having a right angle
configuration in plan view, a first portion of the bracket having
an aperture for receiving a screw to attach the first portion to a
web of the grid runner, a second portion having an aperture for a
screw to attach the second portion to the web of a channel wall
molding, the second portion having a generally horizontal tab
extending from said second portion towards said first portion with
a free edge adapted to engage an edge of an inturned hem of a wall
channel.
14. In combination, a grid runner, a right angle bracket, and a
wall molding having a vertical web and a horizontal flange at a top
of the web, the bracket being separately fixed to the wall molding
with a first screw and to the grid runner with a second screw.
15. The combination as set forth in claim 14, wherein the molding
is a channel.
16. The combination as set forth in claim 15, wherein the channel
has horizontal flanges with inturned hems, said bracket having tabs
adapted to be snap locked into said channel by operation of said
tabs against said hems.
17. A combination as set forth in claim 16, wherein said channel
flanges are of different lengths.
18. The combination as set forth in claim 17, wherein said bracket
has tabs of different lengths corresponding to the different
channel flange lengths.
19. The combination as set forth in claim 18, wherein said bracket
has a short tab at an upper portion of the bracket and short and
long tabs on a bottom portion of the bracket.
20. The combination as set forth in claim 14, wherein the grid
runner has a vertical space between an upper reinforcing bulb and a
lower flange, said bracket being sized to fit between said
reinforcing bulb and flange in a sufficiently tight manner to avoid
perceptible rotational movement therebetween.
21. The combination as set forth in claim 20, wherein said bracket
has a horizontal channel at mid-height to receive a reinforcing
bulb of a grid runner having less height than said first mentioned
grid runner.
22. The combination as set forth in claim 21, wherein said bracket
has preformed holes for receiving self-drilling screws.
23. The combination as set forth in claim 14, wherein said bracket
has an elongated slot for use in seismic zones.
24. A splice plate for a high moment of inertia grid runner
comprising a sheet metal plate, the plate having a generally
rectangular profile and a horizontal length greater than a vertical
height, the plate being formed with a horizontal channel at
mid-height, a vertical slot in a mid-section of the plate including
the horizontal channel, the slot forming a line of weakness to
enable a technician to manually bend the plate into a right angle,
the slot having a width sufficient to avoid interference between
sections of the channel on opposite sides of the slot when the
plate is bent with the channel projecting into the space towards
which the plate sections are bent, the plate sections having a
plurality of through holes for accepting self-drilling screws for
attaching the plate to a grid runner.
25. A sheet metal bracket for suspending a first grid runner from a
second grid runner extending over and crosswise to the first grid
runner, the bracket having a generally right angle configuration in
plan view, an upper portion of the bracket having a plurality of
holes for receiving self-drilling screws for attaching the second
grid runner, the first portion being integrally attached to the
second portion and extending below the second portion, the first
portion having an offset bend below said second portion and a flat
part below said offset, said flat part having through holes for
receiving self-drilling screws for fixing said flat part to a web
of the first grid runner.
Description
BACKGROUND OF THE INVENTION
[0001] The invention relates to suspended ceilings and, in
particular, to grid elements that eliminate or reduce the number of
mid-span suspension wires or like elements required to adequately
support the ceiling assembly.
PRIOR ART
[0002] Commonly, the grid of a suspended ceiling is supported by
wires depending from overhead structure such as an overlying floor
or roof. There are circumstances, as in corridors, where the plenum
or space above the ceiling is occupied by utilities, such as air
and wire ducts, making it difficult or impractical to use wires for
carrying the weight of a ceiling. In other circumstances, there may
only be a limited number of places to attach wires to the overhead
structure and/or to the grid elements. In still other
circumstances, labor and overall installation costs can be lowered
where the number of wires needed for an installation is
reduced.
[0003] There have been proposals such as disclosed in U.S. Pat. No.
7,240,460 and U.S. patent publication US 2010/0257807 A1 for free
span suspended ceilings.
SUMMARY OF THE INVENTION
[0004] The invention provides a ceiling grid system with high
moment of inertia grid runner, end brackets and wall mounted runner
end supports. Optional elements of the system include splice plates
and runner-to-runner cross hanger brackets. The disclosed system is
capable of spanning an area without or with limited overhead wire
support.
[0005] In the disclosed embodiment, the high moment of inertia grid
runners are primarily used as main runners or tees that cooperate
with cross runners in a generally conventional manner. End brackets
are manually attached to main runners typically at the grid
installation site after the main runners are confirmed to fit or
have been cut to fit the span across which they are to be
installed.
[0006] Preferably, an end bracket interfits with the physical
characteristics of the main runner so that only a single screw
fastener is required to rigidly fix the bracket to the runner.
[0007] The disclosed grid runner end supports are in the form of
roll formed sheet metal channels that are affixed to the walls at
the edge of the ceiling. The channel flanges can be of different
widths so that the channel can be oriented with a wide or narrow
flange visible from the space below the ceiling. The flanges have
inturned hems that are engaged by tab elements of the end brackets
for a quick snap-in provisional mounting. An end bracket can be
locked on the channel at a desired location with a screw fastener
through a web of the channel.
[0008] In moderate span length applications such as in a corridor
of 8 foot (or metric equivalent) for an acoustical ceiling, the
disclosed system can eliminate the need for intermediate overhead
support wires or like members. In longer spans, the system can
reduce the number of suspension wires that would otherwise be
required. For such longer spans, a splice plate is provided to
enable the high moment of inertia grid runner to be connected
end-to-end. Additionally, the splice plate can be bent into a right
angle for connecting intersecting grid runners to the main
runner.
[0009] A cross brace clip is disclosed that suspends a high moment
of inertia grid runner with an identical grid runner to reduce the
number of necessary suspension wires and/or enable a main runner to
be suspended where no directly overhead structure is available for
its support.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic perspective view of a corridor ceiling
embodying aspects of the invention;
[0011] FIG. 2 is an enlarged fragmentary perspective view of an end
area of grid runners and a support channel of FIG. 1;
[0012] FIG. 3 is an enlarged fragmentary perspective view of a main
grid runner with a narrow lower flange and a support channel
inverted from that shown in FIG. 2;
[0013] FIG. 4 is an elevational view of an end clip for a main
runner shown in a pre-bent condition;
[0014] FIG. 5 is an edge view of the clip of FIG. 4;
[0015] FIG. 6 is a top view of the clip of FIG. 4;
[0016] FIG. 7 is an elevational view of a splice plate for the main
runner;
[0017] FIG. 8 is an edge view of the splice plate of FIG. 7;
[0018] FIG. 9 is a fragmentary perspective view of two main runners
joined with the splice plate of FIG. 7;
[0019] FIG. 10 is a perspective view of main runners intersecting
at 90 degrees and joined by the splice plate of FIG. 7;
[0020] FIG. 11 is a view similar to FIG. 10 with a cross-runner
joined to a main runner with the splice plate of FIG. 7;
[0021] FIG. 12 is a perspective view of a cross brace clip for
supporting a main runner from an identical transverse main
runner;
[0022] FIG. 13 is a front view of the cross brace clip;
[0023] FIG. 14 is a side view of the cross brace clip; and
[0024] FIG. 15 is a top view of the cross brace clip.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] FIG. 1 illustrates a suspended ceiling grid 10 suitable for
supporting conventional acoustical panels or tiles in a corridor
11. It will be understood that various aspects of the invention are
applicable to suspended ceilings apart from hallways or corridors
and the like. By way of example, the corridor 11 can be nominally 8
foot in width (or metric equivalent). The grid 10 comprises
parallel main runners 12 located on 4 foot centers. Cross runners
13, nominally 4 foot long, extend transversely between the main
runners 12. Nominal 2 foot cross runners 14 are disposed between
cross runners 13.
[0026] As is conventional, cross runners 13, 14 have end connectors
assembled in receiving slots 17 of the main runners 12 and cross
runners 13. Ends of the main runners 12 and cross runners 14 are
supported by wall channels 19.
[0027] The main runners 12 have the general cross section of an
inverted tee with a hollow upper generally oval reinforcing bulb
21, a vertical web 22 depending from the bulb, and a flange 23
symmetrically disposed about a lower edge of the web. The
illustrated bulb 21 is substantially wider than it is tall. By way
of example, but not limitation, the main runner 12 can have a
height of about 23/4 inch which, when compared to a typical 1.640
inch height conventional intermediate duty main grid runner, is
relatively tall. The height of the main runner 12, width of its
reinforcing bulb 21 and heavier gauge results in a runner that has
a high moment of inertia about its longitudinal bending axis.
Consequently, the runner 12 can support a relatively high load
distributed along its length. For example, the main runner 12,
formed of 0.022 inch thick G-30 hot-dipped galvanized steel place
on 4 foot centers such as is shown in FIG. 1 can readily support an
acoustical ceiling of conventional tile. The illustrated main
runner 12 can support 12 pounds per foot across a span of 8 foot
without intermediate support wires, straps, rods or the like.
[0028] The ceiling load on a main tee 12 is transferred at each end
to a respective wall channel 19 through an end bracket 26. The end
bracket 26 is shown separately in FIGS. 4-6 and with main and cross
runners 12, 13 in FIGS. 2 and 3. The end bracket 26 is preferably a
sheet metal stamping. The bracket 26 can be marketed in the
generally flat configuration illustrated in FIGS. 4-6 making it
easier for a technician to carry a plurality of the brackets in a
pouch or box. For use, the technician manually bends the bracket 26
across a vertical line determined by a center line of a vertical
slot 27 that serves locally to weaken the bracket for this bending
purpose. A portion 28 of the bracket 26 to the left of the slot 27
in FIG. 4 is engageable with a main grid runner 12 and a portion 29
to the right is engageable with a wall channel 19. The bracket 26
has a central horizontal shallow channel 31 with an elevation and
width enabling it, on the left portion 28 to register with a
reinforcing bulb 32 of a conventional grid runner of nominal 11/2
inch height as shown in FIG. 2. A narrow horizontal slot 33 enables
an upper region of the left bracket portion 28 to be removed for
clearance purposes by cutting the region off at the dotted lines
34, 35. Two other horizontal slots 36, 37 can be used in a seismic
application with a screw located in either slot and an associated
grid runner. Holes 38 are provided to receive screw fasteners for
fixing the bracket 26 to a grid runner 12, 13 and to the web of a
wall channel 19.
[0029] The wall channel 19 is preferably roll formed of sheet metal
of, for example, G-30 hot dipped galvanized steel of 0.020 inch
thickness. The illustrated channel 19 has flanges 41, 42 of
different widths and extending generally perpendicularly from a
common web 43. The wider flange 41 is, for example, nominally 1
inch wide and the narrow flange 42 is nominally 1/2 inch wide.
These flange dimensions correspond to the flange face width of
standard and narrow face commercially available grid common in the
industry. The channel flanges 41, 42 have inturned hems 44
associated with marginal edges 45 of the metal strip forming the
channel 19. The flanges 41, 42 are spaced to receive the height of
the main runner 12.
[0030] As shown in FIG. 1, the channels 19 are secured to a wall 15
at ceiling height with one of their flanges 41 or 42 at or
essentially at the plane of the grid surfaces which remain visible
when ceiling tile are installed on the grid flanges. The other
flange 42 or 41 is situated above this visible plane. The main
runners 12 may be supplied with a length that exceeds a standard
corridor width. For example, if the corridor under construction has
a nominal 8 foot width, main runners 12 can be provided at a length
of 8 foot 6 inches, so that any actual run out of the corridor can
be accommodated. End brackets 26 are field installed on the main
runners 12 so that the main runners can be first properly cut to
length, typically at each end, to center the grid 10 as dictated by
slots 17 in the main runners. The cross runner connector receiving
slots 17 (FIG. 2) are spaced along the length of the main runner 12
on, for example, 6 inch centers.
[0031] The end brackets 26 have resilient tabs 48-50 on upper and
lower edges of the channel engaging portion 29. The upper tab 48
extends the full length of the portion 29 and a lower middle tab 49
extends between outlying lower tabs 50. With reference to FIG. 2,
the outlying lower tabs 50 are proportioned to snap into engagement
with the inner edges 45 of the hem 44 of the wide channel flange 41
and the upper tab 48 is proportioned to snap into engagement with
the narrow flange hem edge 45 when the bracket portion 29 is pushed
into the channel 19. This snap fit is a convenience to the
installer since the bracket 26 (and the main runner 12 if it is
attached) is/are immediately held in the channel while being
horizontally adjustable. When in a proper position, the bracket 26
is fixed to the channel web 43 with a self-drilling screw 40 or
other suitable fastener through a hole 38 in the portion 29. The
bracket 26 can be fixed to a main runner 12 with a single
self-drilling screw 40. Upper and lower edges 52, 53 of the runner
engaging portion 28 of the end bracket are proportioned to fit
closely with the bottom of the reinforcing bulb 21 and top of the
flange 23 when positioned against the main runner web 22. When held
against the web 22 by a single self-drilling screw 40 or other
fastener positioned in a hole 38, the bracket 26 cannot perceptibly
rotate relative to the main runner 12 and, consequently, the main
runner cannot droop at the bracket under the weight of the
ceiling.
[0032] Typically, the channel 19 is secured to a wall by
self-drilling drywall screws 55 (FIG. 2) through the channel web
43, any wall facing material such as drywall, and into studs 54. An
upper flange 42 or 41 of the channel 19 stiffens the channel web 43
and prevents it from pulling away from the wall to which it is
attached due to the weight of the ceiling. Consequently, there is
no need to align a bracket 26 or, more importantly, a grid runner
12, with a wall stud 54 (FIG. 1) so that the bracket would be
anchored directly to a stud.
[0033] From the foregoing, it will be seen that for the spans of
about 8 feet the runners 12 and the acoustical ceiling elements
they carry are supported exclusively at their ends. The brackets 26
are capable of fully providing this support although a support
contribution can be provided by a lower channel flange 41 or
42.
[0034] In FIG. 3, a main runner 112 has a narrow flange face as
would the other main and cross runner in a ceiling installation.
The wall channel 19 is inverted from its position in FIG. 2. In
this orientation, the narrow flange 42 will be visible from below
and will match the appearance of the grid runners where they are of
the narrow face design. In instances where the wall channel 19 is
of the orientation in FIG. 3, the end bracket tabs 50 are bent up
by the installer and the middle tab 49 can engage the adjacent hem
edge 44 of the narrow flange 42.
[0035] In the foreground of FIG. 2 is illustrated the end bracket
26 supporting a conventional cross runner 14. The horizontal
channel 31 is proportioned to receive a reinforcing bulb 32 of the
runner 14 while a lower part of the portion 28 abuts a web 58 of
the runner. For seismic service, a screw can be positioned in the
slot 37 and the reinforcing bulb.
[0036] FIGS. 7 and 8 illustrate a splice plate 61 useful for
joining the ends of a pair of main runners 12 in the manners
illustrated in FIGS. 9 and 10. The splice plate 61 is generally
rectangular in front view, being formed, for example, of 0.030 inch
gauge hot-dipped galvanized steel sheet. The plate 61 has notches
62 along its upper and lower edges at its mid-section. A shallow
horizontal rib or channel 63 is stamped in the body of the plate
61. A central vertical slot forms a line of weakness to permit the
plate 61 to be manually bent into a right angle. Elongated
horizontal slots 66 are stamped in the plate channel 63 on both
sides of the vertical slot 64. Several holes 67 are provided for
screws used to attach the plate to a grid runner. FIG. 9
illustrates the plate 61 joining a pair of main runners 12 together
in end-to-end alignment. Upper and lower edges 68, 69 of the plate
61 fit closely between the reinforcing bulb 21 and the flange 23
when the plate is abutted against the web 22 of a main runner 12.
The fit of the plate 61 thereby prevents any perceptible rotational
movement relative to the main runner to which it is attached. Any
of the holes 67 or slot 66 may be used to accept a screw for
attaching the plate to a main runner 12.
[0037] FIG. 10 illustrates use of the plate 61 to join a main
runner 12 with an intersecting main runner. Note that the width of
the slot 64 avoids interference between areas of the channel 63
when the plate 61 is bent into a right angle.
[0038] FIG. 11 illustrates use of the splice plate 61 to join a
main runner 12 with an intersecting conventional cross runner 13 or
14. The channel 63 is configured to receive the reinforcing bulb 32
and a lower part of the plate half to abut the web 58 of the
conventional grid runner.
[0039] A physical situation may exist where a main runner 12 cannot
be supported exclusively at its end. For example, may be an absence
of a suitable attachment point for a suspension wire or strap
overlying the main runner or runners involved. FIG. 12 illustrates
a cross brace clip 71 that can be useful in such situations. The
clip 71, shown in detail in FIGS. 13-15, is a monolithic sheet
metal stamping of, for example, 0.050 inch hot dipped galvanized
steel. The clip 71 has the general geometry of a right angle. An
upper planar part 72 of the clip 71 has several holes 73 for
receiving self-drilling screws for attachment to the web 22 of a
main runner 12. Upper and lower edges of the part 72 are spaced to
closely fit between the reinforcing bulb 21 and flange 23 of a main
runner 12 so that the part cannot perceptively rotate relative to
the main tee when it abuts the web 22. The clip 71 includes a
triangular extension 74 in a vertical plane perpendicular to the
planar part 72. An offset web 76 joins the extension 74 to a
depending planar part 77. Holes 78 in the depending planar part 77
receive self-drilling screws for attachment to the web 22 of a main
runner 12 below and transverse to the main runner to which the
upper planar part 72 is attached. It will be seen from FIG. 12 that
the cross brace clip 71 supports the lower main runner 12 from the
overlying main runner 12.
[0040] 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.
* * * * *