U.S. patent application number 15/599582 was filed with the patent office on 2018-11-22 for linear metal ceiling components.
The applicant listed for this patent is USG Interiors, LLC. Invention is credited to Peder J. Gulbrandsen, Mark R. Paulsen, Abraham M. Underkofler.
Application Number | 20180334803 15/599582 |
Document ID | / |
Family ID | 62749152 |
Filed Date | 2018-11-22 |
United States Patent
Application |
20180334803 |
Kind Code |
A1 |
Underkofler; Abraham M. ; et
al. |
November 22, 2018 |
LINEAR METAL CEILING COMPONENTS
Abstract
A linear metal ceiling system having improved carrier and pan
geometries that afford improved versatility in pan widths and
shapes, and improved pan retention force. Accessories for joining
carriers together and for attaching perimeter trim strips are
disclosed.
Inventors: |
Underkofler; Abraham M.;
(Salem, WI) ; Gulbrandsen; Peder J.; (Aurora,
IL) ; Paulsen; Mark R.; (Waukegan, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
USG Interiors, LLC |
Chicago |
IL |
US |
|
|
Family ID: |
62749152 |
Appl. No.: |
15/599582 |
Filed: |
May 19, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 9/225 20130101;
E04B 9/065 20130101; E04B 9/0435 20130101; E04B 9/127 20130101;
E04B 9/0478 20130101; E04B 9/30 20130101; E04B 9/10 20130101; E04B
2103/06 20130101; E04B 9/363 20130101 |
International
Class: |
E04B 9/06 20060101
E04B009/06; E04B 9/04 20060101 E04B009/04; E04B 9/10 20060101
E04B009/10; E04B 9/22 20060101 E04B009/22; E04B 9/30 20060101
E04B009/30 |
Claims
1. A linear metal ceiling system comprising a plurality of
elongated carriers and a plurality of elongated sheet metal pans,
each carrier having a multitude of grips uniformly spaced along a
lower side, alternate grips extending in a longitudinal direction
opposite of a longitudinal direction of intervening grips, each
grip being cantilevered from a base such that a grip forms part of
a boundary of a notch overlying the grip, each grip having an
increasing height zone adjacent a distal end and a horizontal zone
with a length extending inward of the increasing height zone, each
pan having a bottom and two sides on opposite margins of the
bottom, at least one of the pan sides having an inturned flange
adjacent an upper edge of a side, the flanges having a decline in a
direction towards a center of a width of the pan and terminating at
an edge whereby when the pan is installed on a grip the edge rests
on the horizontal zone, the flange and increasing height zone of a
grip are adapted to mutually interfere when a force urging the
flange off of the grip exists, and the notch is constructed and
arranged to allow the edge to engage the horizontal zone at
locations along the length of the horizontal zone.
2. A linear metal ceiling system as set forth in claim 1, wherein
angles, measured from a horizontal reference, of the increasing
height zone of the grip and decline of the flange are substantially
equal.
3. A linear metal ceiling system as set forth in claim 1, wherein
the carrier has an inverted U-shaped cross-section and at each
longitudinal location of a grip there is a pair of transversely
aligned laterally spaced grips.
4. A linear metal ceiling system as set forth in claim 1, wherein
the grips are arranged on 2 inch centers and are adapted to support
pans having nominal widths ranging from 2 inches to 12 inches in 2
inch increments.
5. A splice plate for a linear metal ceiling pan carrier with an
inverted U-shaped cross-section characterized by a flat top and
divergent flat side portions, the splice plate being formed of
sheet metal with a top and divergent sides in a cross-section
configuration that is complementary to the carriers such that the
splice plate can simultaneously abut the top and side portions of
two carriers to thereby align the two carriers, the splice plate
having receiving holes in the top and sides for receiving fasteners
used to join the splice plate to the carriers.
6. A splice plate as set forth in claim 5, wherein the splice plate
sides adjacent an end of the splice plate have edges lying in a
common plane that has an inclination substantially the same as an
inclination of the splice plate sides.
7. A clip for attaching a channel-shaped trim strip to a pan
carrier for a linear metal ceiling, the clip being formed of a
unitary sheet metal body, the clip having a mounting section
configured to seat on a top and abut the side of an inverted
U-shaped carrier, a support section including a vertical leg and a
horizontal extension, the leg extending below and above a level of
the mounting section, a main part of the leg lying in a
substantially vertical plane, the extension spacing the leg from
the mounting section, the leg having upper and lower ends with
short flanges extending in a direction that the extension extends
to engage inturned hems on flanges of the trim strip, the extension
being connected to the mounting section by a pair of vertically
spaced lands separated by a slot in the body whereby the support
section can be displaced relative to the mounting section about a
vertical line represented by the lands when the body is bent at the
lands.
8. A clip as set forth in claim 7, wherein the mounting section has
holes for receiving fasteners for allowing the clip to be fastened
to a carrier.
Description
BACKGROUND OF THE INVENTION
[0001] The invention relates to linear metal suspended ceiling
systems.
PRIOR ART
[0002] Linear metal ceilings typically comprise spaced parallel
carriers and elongated U-shaped pans attached to and extending
transversely to the carriers. It is known to provide the carriers
with integral grips uniformly spaced along their lower sides for
engagement with longitudinal edges of the pans. The pans have been
available in various widths although, sometimes, their free use has
been limited by the geometry of the carrier grips. Frequently,
prior linear ceiling systems have had limited resistance to seismic
forces and/or wind loads.
SUMMARY OF THE INVENTION
[0003] The invention provides a linear metal ceiling system that
affords a wide choice in pan widths, either uniform or mixed,
various pan profiles, and a strong inter-engagement between a
carrier and the pans. As disclosed, the carrier has a relatively
short center-to-center distance between grips so that narrow pans
using adjacent grips and wide pans using spaced grips are readily
accommodated.
[0004] Also, as disclosed, the grips and panels have unique
profiles that when interconnected, afford a relatively high
retention force, being far greater than that available with at
least some prior arrangements. The grips, additionally, can
accommodate a wide variety of panel edge profiles so that a large
selection of pan shapes and sizes is practical.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a fragmentary perspective view, from above, of a
linear metal ceiling system embodying the invention;
[0006] FIG. 2 is a fragmentary side view of a carrier;
[0007] FIG. 2A is an enlarged fragmentary view of a typical grip of
the carrier;
[0008] FIG. 3 is an end view of the carrier;
[0009] FIG. 4 is an end view of one form of pan of the
invention;
[0010] FIG. 5 is a fragmentary view of a plurality of the pans of
FIG. 4 installed on a carrier;
[0011] FIG. 6 is an end view of another form of a pan of the
invention;
[0012] FIG. 7 is a fragmentary view of a plurality of the pans of
FIG. 6 installed on a common carrier;
[0013] FIG. 8 is a perspective view of a carrier splice plate of
the invention;
[0014] FIG. 9 is a side view of the splice plate;
[0015] FIG. 10 is an end view of the splice plate;
[0016] FIG. 11 is a perspective view of a perimeter trim clip of
the invention; and
[0017] FIG. 12 is a side view of the clip of FIG. 11;
[0018] FIG. 13 is an end view of a carrier mounting portion of the
clip of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] A linear metal ceiling system 10, shown in FIG. 1, as
carriers 11 supporting U-shaped panels 12. The system 10 is
typically suspended by wires 13 attached to the carriers 11 and to
overhead superstructure (not shown). The carriers 11 are in spaced
parallel relation, usually in a common horizontal plane, and the
pans, in parallel relation, extend transversely to the
carriers.
[0020] FIGS. 2 and 3 illustrate features of the carriers 11. A
carrier 11, which can be a roll formed sheet metal product, has an
inverted U-shaped cross-section with sides 16 and a top or web 17.
A carrier 11 can have a length of 10 feet, for example, a height of
15/8 inch and a width of nominally 1 11/16 inch, for example. The
carrier 11 can be made of 20 gauge aluminum 3003/3105 H14/H24 for
exterior applications hot dipped galvanized (HDG) steel for
interior applications.
[0021] An upper portion 18 of a side 16 is cantered outwardly, for
example, at an angle of 118 degrees from the plane of the top 17.
Lower vertical portions 19 of the sides 16 are punched or otherwise
formed with grips located along the full length of the carrier 11
aligned side-to-side for attaching the pans 12. The grips 21,
supported on a common base 22, are arranged in oppositely extending
pairs or sets with a center-to-center distance from one pair to an
adjacent pair being, for example, 2 inches.
[0022] Referencing FIG. 2A, a grip 21 is characterized by the
presence of an associated overlying generally rectangular throat or
notch 23. A notch 23 is bounded by an upper horizontal edge 24, an
inner vertical edge 26, an inner horizontal lower edge 27 and an
outer lower inclined edge 28, the latter two elements formed by the
grip 21 itself.
[0023] The inclined grip edge 28 lies at an angle of between 30
degrees and 60 degrees and preferably is about 45 degrees from the
horizontal so that the grip edge rises in a direction towards a
distal end 29.
[0024] A lower edge 31 of a grip 21 is preferably beveled to
facilitate reception of a pan and to provide clearance for some
styles of pans.
[0025] Typically, pans are supplied in 10 foot lengths. Illustrated
pans 12 can be roll formed of 22 gauge aluminum for exterior use
and 24 gauge electrogalvanized steel for interior use.
[0026] FIG. 4 illustrates one style of pan 12a. The pan 12a has a
bottom 33 with a lower face 34 and sides 36. The sides 36 in their
free state are cantered inwardly. Along upper edges, the pan sides
36 have inturned lips or flanges 37. Preferably, each flange 37
lies at an acute angle of between 30 and 60 degrees and preferably
about 45 degrees with its associated side 36. A pan 12a is snapped
onto oppositely extending grips 21. It will be understood from FIG.
1, that all of the carriers 11 are aligned with their grips 21
located along common lines transverse to the carriers thereby
enabling a carrier to be snapped onto the grips of adjacent
carriers 11.
[0027] The style of pan 12a shown in FIGS. 4 and 5 can have a
nominal width between 2 inches and 12 inches with the available
widths being stepped in 2 inch increments and a nominal depth of
7/8 inch. Pans with a 4 inch width engage outlying grips 21 of two
adjacent bases 22 and pans wider than 4 inches are free of
attachment to bases intervening those basis to which a wider pan is
attached. As shown in FIG. 5, the canted sides 36 enable the panels
to butt with a closed joint at their lower faces 34.
[0028] The configuration of the inturned flange or hook 37 on the
pan sides 36 and the upturned edges 28 on the grips 21, with their
respective inclinations being complementary, i.e. in the same
direction and within 20 degrees of each other has been discovered
to produce an improved pan retention on a carrier 11. For example,
the pans have been found to withstand loads, oriented to separate a
pan 12a from the pair of grips 21 on opposite sides 16 of the
carrier, of about 180 pounds of force.
[0029] FIGS. 6 and 7 illustrate a lap-style pan 12b. The pan
cross-section is asymmetric with one side having an inturned
inclined flange 37 of the same or substantially the same
orientation as the previously described pan 12a and on an opposite
side 42 having an outwardly extending horizontal flange 43. The
inturned flange 37 is proportioned to fit in a carrier notch 23
under the horizontal flange 43 of an adjacent pan. The notch 23 is
proportioned to receive a relatively wide flange 43 without
interference. A bottom 46 of the pan 12b can have a nominal width
of 15/8 inch to 115/8 inch stepped in 2 inch increments. The
nominal depth of the sides of the pan 12b can be, for example, 7/8
inch or, alternatively, 11/2 inch.
[0030] The geometry of the grips 21 and associated notch 23 can
accept a wide variety of panel shapes in addition to those shown in
FIGS. 5 and 7. For example, the juncture of a panel bottom and its
sides can be rounded, with a larger radius than that shown in FIGS.
4-7 beveled or asymmetrical.
[0031] Referencing FIGS. 8-10, there is shown a splice plate 51 for
joining carriers 11 end-to-end or in perpendicular relation. The
splice plate 51, preferably, is a sheet metal stamping of 18 gauge
HDG steel or 18 gauge aluminum 3002/3105 temper H14-H24. The splice
plate 51 has an inverted U-shape complementary to that of the upper
portion 18 of the carrier 11 so that it fits as a saddle onto the
top 17 of a carrier. The splice plate 51 has a center web 52 and
depending sides 53 that diverge with the same angle as the upper
portions 18 of the carrier 11, each side at an angle of, for
example, 118 degrees from the center web. The center web 52 is
longer than the sides 53 of the splice plate to thereby provide
cantilever tabs 54. Edges 56 of the sides 53 at each end of the
splice plate 51 lie on a common plane oriented at 118 degrees from
the plane of the splice top or center web 52, i.e. at the same
angle as the upper sides or upper portions 18 of the carrier from
the carrier top web 17.
[0032] The splice plate sides 53 and top or center web 52 are
stamped or otherwise formed with a plurality of holes 57 to receive
self-drilling screws or other fasteners to attach the splice plates
to the carriers 11 being joined by the splice plate. Larger holes
58 on the sides 53 are alignable with holes in the carriers 11 and
can receive suspension wires 13 when aligned with suspension wire
holes in a carrier. The splice plate can align and join the ends of
two carriers 11 where a ceiling area dimension in the direction of
the carriers is greater than the standard length of a carrier.
[0033] The splice plate 51 can also be used to join a carrier 11
intersecting another carrier at right angles. The splice plate 51
can be fixed to an end of the intersecting carrier 11, either being
partially cantilevered or with the intersecting carrier being
trimmed to match the geometry of the splice plate edges 56. The
splice plate 51 is fixed to the intersected carrier by abutting the
splice plate edges 56 against the adjacent side of the intersected
carrier and positioning fasteners through holes 57 in the
respective tab 54 into the top of the intersected carrier.
[0034] The splice plate 51 can also serve to locally reinforce a
carrier 11 where a suspension wire 13 is attached by locating and
attaching the splice plate with its holes 58 aligned with the holes
in the carrier before a suspension wire is installed.
[0035] FIGS. 11-12 illustrate a perimeter trim clip 61 for
attaching a trim channel 62, shown in FIG. 11, to a carrier 11. The
trim channel 62 can be of a type known in the industry such as that
marketed by USG Corporation under the registered mark
COMPASSO.RTM.. The clip 61 has a carrier mounting section 63
stamped or otherwise formed of 22 gauge HDG steel, for example, and
a trim channel supporting section 64. The mounting section 63
includes a half saddle portion 66 proportioned to fit over a
carrier 11 flat against both the top 17 and a side upper portion
18. The saddle portion 66 has a horizontal seat 67 engageable with
a carrier top 17 and a downwardly and outwardly extending leg 68
engageable with an upper portion 18 of a side 16 of the carrier 11.
The leg 68 has a plurality of holes 69 and a slot 71 for receiving
self-drilling screws or other fasteners driven through the side
upper portions 18 of the carrier 11 to fix the clip 61 to the
carrier.
[0036] The channel supporting section 64 has a vertical leg 76 with
inturned flanges 77 at the top and bottom of the leg. The leg 76 is
stiffened by a vertical flange 78 extending perpendicularly to a
plane of a main part 79 of the leg 76. At a mid-height, the flange
78 merges with an extension 81. The extension 81 is separated from
an upright plate 82 extending upwardly from the seat 67 of the
saddle portion 66 by a vertical through slot 83 and small bendable
lands 84 at opposite ends of the slot.
[0037] The channel or trim strip 62, typically, a roll formed sheet
metal strip, has an elongated shell or pan configuration with a
relatively wide web 87 and flanges 88 along each longitudinal edge
of the web. The flanges have inturned hems 89 adapted to be snapped
over and be retained by the flanges 77 of the clip leg 76.
[0038] FIGS. 11-12 show the clip 61 in an as-manufactured
configuration which can be used without alteration for situations
such as shown in FIG. 11 where the perimeter trim strip 62 is
desired to be parallel to the pans 12 and perpendicular to the
carriers 11. Alternatively, in situations where the trim strip 62
is to be mounted perpendicularly to the pans 12 and parallel to the
carriers 11, the leg 76 must be re-oriented relative to the
mounting section 63. The leg 76 can be re-oriented so that its
plane is parallel to the plate 82 of the carrier mounting section
63 by bending the extension 81 about a hinge line formed by the
relatively weak lands 84. The flange extension 81 is long enough to
support the leg 76 to a side of a carrier 11 with adequate
clearance. The flange extension 81 can be bent to the left or right
so that a perimeter trim strip 62 can be disposed on either side of
a carrier 11 on which the clip 61 is mounted.
[0039] 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.
* * * * *