U.S. patent application number 16/854184 was filed with the patent office on 2020-12-03 for grid tee for suspended ceiling.
The applicant listed for this patent is Rockwool International A/S. Invention is credited to Scott G. Jankovec.
Application Number | 20200378116 16/854184 |
Document ID | / |
Family ID | 1000004858111 |
Filed Date | 2020-12-03 |
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United States Patent
Application |
20200378116 |
Kind Code |
A1 |
Jankovec; Scott G. |
December 3, 2020 |
GRID TEE FOR SUSPENDED CEILING
Abstract
A suspended ceiling grid main runner is provided that has a
cross-section generally in the form of an inverted T, with a
central web, a pair of panel support flanges extending from one
edge of the web, and a reinforcing bulb extending from the other
edge of the web. The main runner includes an integrally-formed
interlocking connector, first and second series of longitudinally
extending, spaced apart stitches in the web adjacent to the bulb
and flanges, hemmed flanges including a cap, and an enlarged
reinforcement bulb, which together increase the structural strength
of the main runner sufficient to compensate for a reduction in the
thickness of the metal strip from which the main runner is
formed.
Inventors: |
Jankovec; Scott G.;
(Elmhurst, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rockwool International A/S |
Hedehusene |
|
DK |
|
|
Family ID: |
1000004858111 |
Appl. No.: |
16/854184 |
Filed: |
April 21, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62856217 |
Jun 3, 2019 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 9/068 20130101;
E04B 9/127 20130101; E04B 9/10 20130101 |
International
Class: |
E04B 9/10 20060101
E04B009/10; E04B 9/06 20060101 E04B009/06 |
Claims
1. A main runner for a suspended ceiling grid system comprising: a)
a central web formed of two layers of sheet metal having first and
second ends; b) a reinforcement bulb extending from an upper
portion of the central web between the first and second ends of the
central web; c) opposed flanges extending from a portion end of the
central web between the first and second ends of the central web;
d) first and second end connector integral with the central web and
extending from the first and second ends of the central web,
respectively, past the flanges, the first end connector being
displaced out of a plane defined by the central web in a first
direction and the second end connector being displaced out of the
plane defined by the central web in a second direction opposite to
the first direction, each of the first and second end connectors
having a distal edge; e) a strap adjacent each end of the central
web deformed out of the plane of the central web in a direction
opposite to the adjacent end connector, the strap being configured
to receive an end portion of an end connector of a second tee f)
each of the first and second end connectors further comprising a
rectangularly-shaped embossment extending out of a first side of
the end connector, the embossment being defined by a proximal edge,
a distal edge, an upper edge and a lower edge, and first and second
spaced-apart locking tabs each having a proximal tapered camming
surface and distal locking surface extending out of a second side
of the end connector, such that the distal locking surface of the
locking tabs engage the distal edge of the end connector of the
second tee.
2. The main runner of claim 1 further comprising a first row of
longitudinally spaced stitches at the upper end of the web adjacent
the bulb and a second row of longitudinally spaced stitches at the
lower end of the web adjacent the flanges, with the stitches in the
first row being staggered relative to the stitches in the second
row.
3. The main runner of claim 1 further comprising a lower cap is
applied to the flanges so that the free edges of the flanges are
bent back on themselves along with the edges of the cap to provide
a hemmed flange.
4. The main runner of claim 2 further comprising a lower cap is
applied to the flanges so that the free edges of the flanges are
bent back on themselves along with the edges of the cap to provide
a hemmed flange.
5. The main runner of claim 1 wherein the main runner has an
overall height of 1.640'' and the bulb has a height of 0.515'' and
rounded upper corners.
6. (canceled)
7. The main runner of claim 2 wherein the main runner has an
overall height of 1.640'' and the bulb has a height of 0.515'' and
rounded upper corners.
8. The main runner of claim 3 wherein the main runner has an
overall height of 1.640'' and the bulb has a height of 0.515'' and
rounded upper corners.
9. The main runner of claim 4 wherein the main runner has an
overall height of 1.640'' and the bulb has a height of 0.515'' and
rounded upper corners.
10. The main runner of claim 1 wherein the main runner is made of a
sheet material having a thickness of 0.012''.
11. The main runner of claim 2 wherein the main runner is made of a
sheet material having a thickness of 0.012''.
12. The main runner of claim 3 wherein the main runner is made of a
sheet material having a thickness of 0.012''.
13. The main runner of claim 4 wherein the main runner is made of a
sheet material having a thickness of 0.012''.
14. The main runner of claim 5 wherein the main runner is made of a
sheet material having a thickness of 0.012''.
15. (canceled)
16. The main runner of claim 7 wherein the main runner is made of a
sheet material having a thickness of 0.012''.
17. The main runner of claim 8 wherein the main runner is made of a
sheet material having a thickness of 0.012''.
18. The main runner of claim 9 wherein the main runner is made of a
sheet material having a thickness of 0.012
Description
BACKGROUND
[0001] The present invention relates to a beam or runner having a
generally inverted T cross section that is used in a support grid
for suspended ceilings.
[0002] Suspended ceilings typically require a support grid
comprising a plurality of interconnected beams for supporting
ceiling tiles or panels, light fixtures, air diffusers, etc. The
beams, also referred to as runners or tees, have a generally
inverted T-shape, with a reinforcing bulb at the top, a vertical
web extending downwardly from the bulb, and opposed horizontal
flanges at the bottom of the web for supporting drop-end ceiling
panels. The beams also typically include connectors on their ends
to permit end-to end connection between adjacent beams.
[0003] The beams are typically made in a roll-forming operation in
which a flat strip of sheet metal is sequentially deformed into a
tee that is symmetrical in cross- section about its vertical axis,
with the web having a double layer of sheet material and the
opposed flanges each having a single layer of sheet material, as is
well known in the art.
[0004] Efforts are continuously being made to reduce the
manufacturing costs of the grid members. One approach is to reduce
the cost of materials by, e.g., reducing the amount of material
used to make the grid members. This may be done most efficiently by
reducing the thickness of the sheet material from which the grid
members are formed. However, if the thickness of the sheet material
is reduced, care must be taken to insure that such a reduction in
thickness does not compromise the structural integrity of a ceiling
grid system assembled from such grid members.
SUMMARY
[0005] By way of the present disclosure, a main runner for a
suspended ceiling grid system is provided having a combination of
features that permit a reduced thickness of the sheet material from
which the main runner is formed, while maintaining the structural
characteristics of the min runner. This results in a runner that is
more economical to manufacture (because less material is required),
is easier to handle, particularly in bulk or carton quantities
(because each runner is lighter in weight), and is easier to
cut.
[0006] A beam or grid tee has a cross-section generally in the form
of an inverted T, with a central web of a double thickness of sheet
metal, a pair of panel support flanges extending from one edge of
the web, and a reinforcing bulb extending from the other edge of
the web.
[0007] In a first aspect, a main runner according to the present
disclosure includes integrally-formed first and second end
connectors extending from the first and second ends of the central
web, respectively, past the flanges. The connectors facilitate
end-to-end attachment of a first main runner to a second main
runner. The first end connector is displaced out of a plane defined
by the central web in a first direction and the second end
connector is displaced out of the plane defined by the central web
in a second direction opposite to the first direction, with each of
the first and second end connectors having a distal edge.
[0008] A strap adjacent each end of the central web deformed out of
the plane of the central web in a direction opposite to the
adjacent end connector, the strap being configured to receive an
end portion of an end connector of a second tee.
[0009] Each of the first and second end connectors further
comprises a rectangularly-shaped embossment extending out of a
first side of the end connector, the embossment being defined by a
proximal edge, a distal edge, an upper edge and a lower edge. First
and second spaced-apart locking tabs, each having a proximal
tapered camming surface and distal locking surface, extend out of a
second side of the end connector, the distal locking surface being
substantially in alignment with the proximal edge of the
embossment, such that the distal locking surface of the locking
tabs engage the distal edge of the end connector of the second
tee.
[0010] In another aspect, the two layers of forming the web of the
beam are secured to each other by a first row of longitudinally
spaced stitches at the upper end of the web adjacent the bulb and a
second row of longitudinally spaced stitches at the lower end of
the web adjacent the flanges, with the stitches in the first row
being staggered relative to the stitches in the second row.
[0011] In another aspect, a lower cap is applied to the flanges so
that the free edges of the flanges are bent back on themselves
along with the edges of the cap to provide a hemmed flange.
[0012] In another aspect, the vertical dimension of the bulb is
increased and the upper corners of the bulb are rounded.
[0013] Other features and advantages will become apparent upon
reference to the drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a main runner for suspended
ceiling grid system in accordance with the present disclosure.
[0015] FIG. 2 is a side view of the main runner of FIG. 1.
[0016] FIG. 3 is a cross-sectional view of the main runner taken
along line 3-3 of FIG. 2.
[0017] FIG. 4 is an end view of the main runner of FIG. 1.
[0018] FIG. 5 is an enlarged cross-sectional view of an end
connector of the main runner taken along line 5-5 of FIG. 2.
[0019] FIG. 6 is an enlarged fragmentary portion of the end view of
FIG. 3 showing details as to the hemmed flange.
[0020] FIG. 7 is an enlarged fragmentary portion of the end view of
FIG. 3 showing details as to the reinforcing bulb.
DETAILED DESCRIPTION
[0021] With reference to FIGS. 1-7, a main runner or tee 10 for use
in a suspended ceiling is disclosed comprising a reinforcing bead
or bulb 12, a central web 14, and a pair of opposed flanges 16 for
supporting ceiling panels or tiles, all as is well known in the
art.
[0022] In keeping with a first aspect, the grid member includes
integrally-formed first and second end connectors 18 extending from
the first and second ends of the central web 14, respectively, past
the flanges 16. With reference to FIG. 2, only a single end
connector 18, extending from the left end of the main runner 10, is
shown. As seen in FIG. 5, the first end connector 18 is displaced
out of a plane defined by the central web 14 in a first direction
"X", while the second end connector would be displaced out of the
plane defined by the central web in a second direction opposite to
the first direction "X". Each of the first and second end
connectors have a distal edge 20.
[0023] A strap 22 adjacent each end of the central web 14 is
deformed out of the plane of the central web in a direction "Y"
opposite to the adjacent end connector, so that the strap 22 is
configured to receive an end portion 24 of an end connector of a
second tee.
[0024] Each of the first and second end connectors 18 further
comprises a rectangularly-shaped embossment 26 extending out of a
first side of the end connector, the embossment being defined by a
proximal edge, a distal edge, an upper edge and a lower edge. First
and second spaced-apart locking tabs 28, each having a proximal
tapered camming surface 30 and distal locking surface 32, extend
out of a second side of the end connector, such that the distal
locking surface 32 of the locking tabs 28 engage the distal edge 20
of the end connector of the second tee.
[0025] In keeping with a second aspect, the two layers of the web
14 are preferably secured to each other by means of locking
stitches or lances 34 that mechanically join together the two
layers of the web 14, thus providing the main runner 10 with added
resistance to torque. The stitches 34 may be of any configuration
known in the art. In one embodiment, the stitches have a
configuration such as that shown in U.S. Pat. No. 5,979055, which
is incorporated herein by reference.
[0026] More specifically, the two layers of forming the web 14 of
the main runner 10 are secured to each other by a first row 36 of
longitudinally spaced stitches 34 at the upper end of the web 14
adjacent the bulb 12 and a second row 38 of longitudinally spaced
stitches 34 at the lower end of the web 14 adjacent the flanges 16,
with the stitches 34 in the first row 36 being staggered relative
to the stitches 34 in the second row 38, Placing each row of
stitches 34 as close to the adjacent bulb 12/flanges 16 is desired
so as to maximize the spacing "D" between the two rows of stitches.
The spacing between the two rows 36, 38, together with the stitches
34 in one row being staggered relative to the stitches 34 in the
other row, provide greater rigidity and also avoids stitches in the
area of the slots 40 that receive the connectors for cross tees
associated with the main runner in the assembled suspension grid,
thus avoiding potential interference between the stitches 34 and
the connectors of the cross tees.
[0027] In another aspect, a lower cap 42 is applied to the flanges
so that the free edges 16a of the flanges 16 are bent back on
themselves along with the edges 42a of the cap 42 to provide a
hemmed flange. This maximizes the surface contact between the cap
42 and the flanges 16, and increases the resistance between the two
parts. This creates a composite action between the cap 42 and the
flanges 1 that causes the two pieces to act as a single unit, such
that the cap 42 does not slip or slide relative to the flanges 16.
The cap 42 also provides for increased section properties for the
main runner 10 due to the additional mass provided by the cap
42.
[0028] In another aspect, the bulb 12 of the runner 10 is modified
to provide for a greater beam height than a standard runner
configuration, More specifically, the vertical dimension of the
bulb 12 is increased and the upper corners 44 of the bulb 12 are
rounded. The rounded corners 44 help to avoid interference between
the bulb 12 and light fixture housings that are supported in the
assembled grid system. In an exemplary embodiment, the bulb 12 has
a height of 0.515'' and a width of 0.250'', with the corners of the
bulb having a radius of 0.093'', while the runner has an overall
height of 1.640''.
[0029] As noted above, the enhanced strength provided to a main
runner having the combination of features described above permit
the runner to be formed of thinner material than the prior art
runner without compromising the beam strength of the runner. By way
of example, the thickness of the sheet material from which the main
runner is roll formed may be reduced on the order of 20% (e.g.,
from 0.015'' to 0.012'')
[0030] Thus, an improved main runner or beam for a suspended
ceiling grid has been provided. While the main runner has been
described in terms of certain preferred embodiments, there is no
intent to limit the invention to the same. Instead, the invention
is defined by the scope of the following claims.
* * * * *