Elongated ceiling grid member and ceiling grid assembly including a plurality of elongated ceiling grid members

Abstract

With the ever-increasing number of structural members and room or building accessories to be supported by elongated ceiling grid members and ceiling grid assemblies, there is a need for elongated ceiling grid members, including "perimeter" elongated ceiling grid members, and ceiling grid assemblies having increased strength to adequately support those increased loads.SOLUTION: An elongated ceiling grid member 21 including (1) a screw member receptacle 23 having a pair of parallel spaced apart side walls that are threaded to receive and retain a first screw member, (2) a vertical wall 39 that is parallel to and laterally spaced apart from the pair of side walls, (3) an angled wall that extends outwardly and downwardly from the pair of side walls and is joined to the vertical wall, and (4) a lower portion at a lower end of the vertical wall that is configured to support a ceiling tile.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This invention relates to elongated ceiling grid members and ceiling grid assemblies that include elongated ceiling grid members and are attached to and suspended from ceilings in rooms and other building spaces, such as office spaces, storage areas, and data centers, to serve as a framework for directly and / or indirectly supporting other structural members and / or room or building accessories. In particular, this invention relates to elongated ceiling grid members that (1) can be connected at their ends to form the perimeter of a ceiling grid assembly consisting of parallel and perpendicular rows of elongated ceiling grid members, and (2) can have other structural members and / or room or building accessories attached to them. [Background technology]

[0002] Ceiling grid assemblies, consisting of multiple elongated ceiling grid members connected at their ends to form parallel and perpendicular rows of elongated ceiling grid members, have been in use for several decades. These ceiling grid assemblies are typically attached directly to and suspended from a structure, such as a concrete slab, that provides the ceiling of a room or other building space. The elongated ceiling grid members of these ceiling grid assemblies directly or indirectly support other structural members and room or building accessories, such as lighting fixtures, HVAC conduits, sprinkler systems, etc., within the room or other building space in which they are installed.

[0003] These ceiling grid assemblies include elongated ceiling grid members that form the perimeter of the ceiling grid assembly. These "perimeter" elongated ceiling grid members may be configured differently to form the perimeter of the ceiling grid assembly and therefore may differ from the elongated ceiling grid members that form the "interior" of the ceiling grid assembly. Furthermore, the "perimeter" elongated ceiling grid members are typically connected only (1) perpendicular to each other to form corners of the ceiling grid assembly, or (2) in a T-configuration that includes two of the "perimeter" elongated ceiling grid members positioned end-to-end and one of the "interior" elongated ceiling grid members positioned perpendicular to the two "perimeter" elongated ceiling grid members.

[0004] In many applications, all elongated ceiling grid members, including "perimeter" elongated ceiling grid members, and ceiling grid assemblies must support ever-increasing loads in terms of weight. That is, the rooms and other building spaces that contain these elongated ceiling grid members and ceiling grid assemblies have an ever-increasing number of structural members and rooms or building accessories that must be supported by the elongated ceiling grid members and ceiling grid assemblies within those rooms and other building spaces, and as the number of structural members and rooms or building accessories increases, the loads acting on the elongated ceiling grid members and ceiling grid assemblies increase. Therefore, there is a need in the art for elongated ceiling grid members, including "perimeter" elongated ceiling grid members, and ceiling grid assemblies that have increased strength to adequately support these increased loads. Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention addresses these needs, as well as other needs that will be readily apparent to those skilled in the art. [Means for solving the problem]

[0006] The elongated ceiling grid member of the present invention has a longitudinal axis in the longitudinal direction. Some embodiments of the elongated ceiling grid member include: (1) a screw member receptacle having a pair of spaced-apart side walls (a) extending parallel to the longitudinal direction and spaced apart in a laterally perpendicular direction to the longitudinal direction, and (b) threaded to threadably receive and hold a first screw member; (2) a vertical wall (a) parallel to the pair of spaced-apart side walls and (b) spaced apart in the laterally perpendicular direction from the pair of spaced-apart side walls; (3) a first sloping wall (a) extending laterally outward from one of the pair of spaced-apart side walls and downward in a vertical direction perpendicular to the longitudinal and lateral directions and (b) joined to the vertical wall; and (4) a lower portion (a) at a lower end of the vertical wall in the vertical direction and (b) extending laterally inward from the vertical wall and (c) configured to support a ceiling tile. The first angled wall may extend from one of the pair of spaced apart side walls between a top edge and a bottom edge of the one of the pair of spaced apart side walls.

[0007] A particular embodiment of the present invention may include (a) a second inclined wall having a first end joined to one of the pair of spaced-apart side walls below the vertical junction between the first inclined wall and one of the pair of spaced-apart side walls, and (b) a second end joined to the vertical wall below the vertical junction between the first inclined wall and the vertical wall. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a side perspective view of a long ceiling grid member according to an embodiment of the present invention. [Figure 2] FIG. 2 is a front elevational view of the elongated ceiling grid member shown in FIG. 1. [Figure 3] FIG. 3 is a side elevational view of the elongated ceiling grid member shown in FIGS. 1 and 2. [Figure 4] 4 is a top perspective view of one embodiment of a corner connector capable of vertically connecting two of the elongated ceiling grid members shown in FIGS. 1-3 to one another. FIG. [Figure 5] FIG. 5 is a top view of the corner connector shown in FIG. 4. [Figure 6] FIG. 6 is a side elevational view of the corner connector shown in FIGS. 4 and 5. [Figure 7] 7 is a cross-sectional view of the corner connector shown in FIGS. 4-6 taken along line 7-7 in FIG. 6. [Figure 8] 8 is a cross-sectional view of the corner connector shown in FIGS. 4 to 7 taken along line 8-8 in FIG. 6. [Figure 9] FIG. 9 is another side elevational view of the corner connector shown in FIGS. 4-8. [Figure 10] 10 is a cross-sectional view of the corner connector shown in FIGS. 4-9 taken along line 10-10 in FIG. 9. [Figure 11] FIG. 11 is a bottom view of the corner connector shown in FIGS. 4 to 10. [Figure 12] FIG. 12 is a top perspective view of the assembly of the corner connector shown in FIGS. 4-11 attached to two of the elongated ceiling grid members shown in FIGS. 1-3. [Figure 13] 13 is a front elevation view of the assembly shown in FIG. 12 of the corner connector shown in FIGS. 4-11 attached to two of the elongated ceiling grid members shown in FIGS. 1-3. FIG. [Figure 14] FIG. 4 is a top perspective view of a T-connector that can connect one or two of the elongated ceiling grid members shown in FIGS. 1 to 3 with an "inner" elongated ceiling grid member in a T-form. [Figure 15] FIG. 15 is a top view of the T-connector shown in FIG. 14. [Figure 16] FIG. 16 is a side elevational view of the T-connector shown in FIGS. 14 and 15. [Figure 17] 16 is a cross-sectional view of the T-connector shown in FIGS. 14-16 taken along line 16-16 in FIG. 15. [Figure 18] 17 is a cross-sectional view of the T-connector shown in FIGS. 14-17 taken along line 17-17 in FIG. 15. [Figure 19] FIG. 19 is a front elevational view of the T-connector shown in FIGS. 14-18. [Figure 20] 20 is a cross-sectional view of the T-connector shown in FIGS. 14-19 taken along line 20-20 in FIG. 19. [Figure 21] FIG. 21 is a bottom view of the T-connector shown in FIGS. [Figure 22] 26 is a top perspective view of an assembly of the T-connector shown in FIGS. 14-21 attached to two of the elongated ceiling grid members shown in FIGS. 1-3 and the "inner" elongated ceiling grid member shown in FIGS. 24 and 25. [Figure 23] 22 is a side elevation view of the assembly shown in FIG. 22 of the T-connector shown in FIGS. 14-21 attached to two of the elongated ceiling grid members shown in FIGS. 1-3 and the "inner" elongated ceiling grid member shown in FIGS. 24 and 25. [Figure 24] FIG. 24 is a side perspective view of the "inner" elongated ceiling grid member shown in FIGS. 22 and 23. [Figure 25] FIG. 25 is a front elevation view of the "interior" elongated ceiling grid member shown in FIGS. 22-24. DETAILED DESCRIPTION OF THE INVENTION

[0009] As mentioned above, one embodiment of the elongated ceiling grid member of the present invention, namely the elongated ceiling grid member 21, is shown in at least Figures 1 to 3. The elongated ceiling grid member 21 is configured to be a perimeter member of a ceiling grid assembly.

[0010] The elongated ceiling grid member 21 has a longitudinal axis LA along its longitudinal length and includes a threaded member receptacle 23, an outer sloped wall 35, an inner sloped wall 37, a vertical wall 39, a bottom end wall 41, a lower sloped wall 43, a finger or tab 51, and a finger or tab 53.

[0011] Threaded member receptacle 23 includes sidewall 25, sidewall 27, and bottom end wall 33. In this embodiment of the invention, sidewalls 25 and 27 extend parallel to the longitudinal direction and are spaced apart in a transverse direction perpendicular to the longitudinal direction. Bottom end wall 33 extends between and connects sidewall 25 and sidewall 27 at or near the lowermost edges of sidewall 25 and sidewall 27, as shown in FIGS. 1 and 2 .

[0012] Sidewall 25 includes internal threads 29 and sidewall 27 includes internal threads 31 .

[0013] The female threads 29 and 31 are on parallel vertical planes and are vertically offset so that a threaded member can be threadably received and held between the female threads 29 and 31, as will be described below and as shown in Figures 12 and 13.

[0014] Although in this embodiment of the invention, the screw member receptacle 23 includes parallel side walls 25 and 27 with internal threads 29 and 31, respectively, elongated ceiling grid members in other embodiments of the invention may include structures other than threaded parallel walls that can receive and retain a screw member or other member.

[0015] 2, the outer angled wall 35 extends between and connects the side wall 25 and the upper edge of the vertical wall 39. The outer angled wall 35 extends laterally outward and vertically downward from the side wall 25. In this embodiment of the invention, the upper end of the outer angled wall 35 intersects the side wall 25 between the upper and lower edges of the side wall 25.

[0016] Also in this embodiment of the invention, inner angled wall 37 extends between and connects bottom wall 33 and vertical wall 39. An upper edge of inner angled wall 37 intersects with an edge of bottom wall 33 below side wall 25. A lower edge of inner angled wall 37 intersects with vertical wall 39 below the intersection of outer angled wall 35 and vertical wall 39.

[0017] In this embodiment of the invention, the elongated ceiling grid member 21 includes an outer sloped wall 35 and an inner sloped wall 37 connecting the screw member receptacle 23 and the vertical wall 39, although in other embodiments of the invention, a single sloped wall or three or more sloped walls can connect the screw member receptacle and the vertical wall.

[0018] Vertical wall 39 extends between and connects the lower edge of outer angled wall 35 to the outermost edge of bottom wall 41. In this embodiment of the invention, vertical wall 39 is parallel to side walls 25 and 27 and is spaced laterally outward from side wall 25.

[0019] Vertical wall 39 includes score lines 55. Score lines 55 provide a reference line for screws connecting vertical wall 39 to a building or room wall. Specifically, an installer of a ceiling grid assembly including elongated ceiling grid member 21 can place screws along score lines 55 and tighten the screws to attach vertical wall 39 to the wall. Score lines 55 help prevent the screws from moving or "walking" along the interior vertical surface of vertical wall 39 when the installer begins to turn the screws with a power drill or other tool.

[0020] The lower end wall 41 extends between the lowermost edge of the vertical wall 39 and the lower inclined wall 43 and connects the lowermost edge of the vertical wall 39 and the lower inclined wall 43 .

[0021] The lower sloped wall 43 includes an upper sloped section 45, a middle section 47, and a lower section 49. The upper sloped section 45 extends between the vertical wall 39 and the middle section 47 and connects the vertical wall 39 to the middle section 47. The middle section 47 extends between the upper sloped section 43 and the lower section 49 and connects them. The lower section 49 extends between the middle section 47 and the bottom end wall 41 and connects them to each other. The lower section 49 has an upper end surface 50 configured to support a ceiling tile or other member.

[0022] The lower end wall 41 and the lower angled wall 43 form the lower portion of the elongated ceiling grid member 21 which extends laterally inwardly from the vertical wall 39 .

[0023] A finger or tab 51 extends downwardly from the inner sloped wall 37. A finger or tab 53 extends upwardly from the upper sloped section 45 of the lower sloped wall 43. The fingers or tabs 51 and 53 are configured to receive and engage various types of clips that may be utilized in a ceiling assembly, such as seismic reinforcement clips.

[0024] In this embodiment of the invention, the screw member receptacle 23, outer angled wall 35, inner angled wall 37, vertical wall 39, bottom end wall 41, lower angled wall 43, finger or tab 51, and finger or tab 53 may be unitary and extruded aluminum. In other embodiments of the invention, one or more of these members may be separate members or separate members joined to other members.

[0025] As previously mentioned, one embodiment of a connector for joining two elongated ceiling grid members 21 to form a corner of a ceiling grid assembly, namely corner connector 57, is shown in Figures 4-13.

[0026] The corner connector 57 includes a first arm 59 and a second arm 61. As will be described below, the first arm 59 and the second arm 61 are identical.

[0027] The first arm 59 and the second arm 61 include an upper end wall 63 which, in this embodiment of the invention, is flat and extends along the upper ends of each of the first arm 59 and the second arm 61.

[0028] Orifices 65, 67, 69, 71, and 73 are located in top wall 63. Specifically, orifices 65 and 67 are located in the top wall 63 of first arm 59, orifices 71 and 73 are located in the top wall 63 of second arm 61, and orifice 69 is located at the junction of first arm 59 and second arm 61.

[0029] Orifices 65, 67, 71, and 73 are configured to receive bolts or other fasteners, such as bolts 75, 77, 79, and 81, for attaching corner connector 57 to two elongated ceiling grid members 21, as shown in Figures 12 and 13. Specifically, bolts 75, 77, 79, and 81 are inserted through orifices 65, 67, 71, and 73, and the threads of these bolts are threadably received by threaded member receptacles 23 of the two elongated ceiling grid members 21.

[0030] Orifice 69 is configured to be machined to receive and engage a structural member, such as a rod that hangs from a ceiling structure.

[0031] First arm 59 and second arm 61 each include a sidewall extending downwardly from top wall 63. Specifically, first arm 59 includes sidewalls 83 and 85, and second arm 61 includes sidewalls 87 and 89.

[0032] Portions of sidewalls 83, 85, 87, and 89 have a different slope than the rest of those sidewalls. These differently sloped portions form voids 91 around orifice 65, voids 93 around orifice 67, voids 95 around orifice 69, voids 97 around orifice 71, and voids 99 around orifice 73. These voids result in additional material around each orifice. This additional material increases the "strength" of what might otherwise be a weak point in the bolt / orifice connection.

[0033] Each of side walls 83, 85, 87, and 89 includes a bottom tab. Specifically, side wall 83 includes bottom tab 101, side wall 85 includes bottom tab 103, side wall 87 includes bottom tab 105, and side wall 89 includes bottom tab 107. In this embodiment of the invention, bottom tabs 103 and 105 are contiguous and bottom tabs 101 and 107 are contiguous, although in other embodiments of the invention, bottom tabs 103 and 105 may be spaced apart and bottom tabs 101 and 107 may be spaced apart.

[0034] The bottom tabs 101, 103, 105, and 107 are configured to receive the screw member receptacles 23 of the elongated ceiling grid member 21 therebetween, as shown in Figures 12 and 13. Specifically, the screw member receptacles 23 of the first elongated ceiling grid member 21 are received between the bottom tabs 101 and 103, and the screw member receptacles 23 of the second elongated ceiling grid member 21 are received between the bottom tabs 105 and 107. Receiving these screw member receptacles 23 between their respective bottom tabs resists deformation of these receptacles under heavy loads.

[0035] As mentioned above, a three-arm connector, i.e., three-arm connector 111, that can be used to connect two of the elongated ceiling grid members 21 to another type of elongated ceiling grid member in a T-configuration is shown in Figures 14 to 23.

[0036] An example of another type of elongated ceiling grid member that can be connected to two of the elongated ceiling grid members 21 by the three-arm connector 111 is the elongated ceiling grid member 22 shown in Figures 24 and 25. The elongated ceiling grid member 22 is configured to be the "inner" grid member of the ceiling grid assembly.

[0037] The elongated ceiling grid member 22 includes, from top to bottom, an upper portion 24, a middle portion 26, and a lower portion .

[0038] Upper portion 24 includes a side wall 30, a side wall 32, and a bottom end wall 34. Bottom end wall 34 extends between and connects side walls 30 and 32.

[0039] Side wall 30 includes internal threads 36, and side wall 32 includes internal threads 38. Internal threads 36 and 38 lie in parallel vertical planes and are vertically offset so that a threaded member can be threadably received and held between internal threads 36 and 38.

[0040] Lower portion 28 includes sidewall 48 , sidewall 50 , bottom flange 56 , and bottom flange 58 .

[0041] Sidewall 48 and sidewall 50 are parallel. Sidewall 48 includes internal threads 52, and sidewall 50 includes internal threads 54. Internal threads 52 and 54 lie in parallel vertical planes and are vertically offset so that a threaded member can be threadably received between internal threads 52 and 54.

[0042] Bottom flange 56 extends outwardly from the lowermost edge of side wall 48, and bottom flange 58 extends outwardly from the lowermost edge of side wall 50. In use, bottom flanges 56 and 58 may support a ceiling tile or other structural member.

[0043] The three-arm connector 111 includes a first arm 113, a second arm 115, and a third arm 117. Each of the arms 113, 115, and 117 are identical as described below.

[0044] The first arm 113, the second arm 115, and the third arm 117 include upper end walls 119, which in this embodiment of the invention are flat as shown and extend along the upper ends of each of the first arm 111, the second arm 113, and the third arm 115.

[0045] 14 to 23, orifices 121, 123, 125, 127, 129, 131, and 133 are located in upper end wall 119. Specifically, orifices 121 and 123 are located in a portion of upper end wall 119 of first arm 113, orifices 127 and 129 are located in a portion of upper end wall 119 of second arm 115, orifices 131 and 133 are located in a portion of upper end wall 119 of third arm 117, and orifice 125 is located at the intersection of arms 113, 115, and 117.

[0046] The orifices 121, 123, 127, 129, 131, and 133 are configured to receive bolts or other fasteners for attaching the three-arm connector 111 to the two elongated ceiling grid members 21 and 22, as shown in Figures 22 and 23. Specifically, in this embodiment, bolts 135, 137, 139, 141, 143, and 145 are inserted through the orifices 121, 123, 127, 129, 131, and 133, respectively, and the threaded ends of the bolts are threadedly engaged with the threaded member receptacles 23 of the two elongated ceiling grid members 21 and the top portion 24 of the elongated ceiling grid member 22.

[0047] Orifice 125 is configured to be machined to receive and engage a structural member, such as a rod suspended from a ceiling structure.

[0048] First arm 113, second arm 115, and third arm 117 each include a sidewall extending downwardly from top wall 119. Specifically, first arm 113 includes sidewalls 147 and 149, second arm 115 includes sidewalls 151 and 153, and third arm 117 includes sidewalls 155 and 157.

[0049] Portions of sidewalls 147, 149, 151, 153, 155, and 157 have a different slope than the remainder of those sidewalls. These differently sloped portions form voids 159 around orifice 121, voids 161 around orifice 123, voids 163 around orifice 125, voids 165 around orifice 127, voids 167 around orifice 129, voids 169 around orifice 131, and voids 171 around orifice 133. Similar to voids 91, 93, 95, 97, and 99 described above, voids 159, 161, 163, 165, 167, 169, and 171 provide additional material to "strengthen" the respective bolt / orifice connections.

[0050] Each of the side walls includes a bottom tab. Specifically, side wall 147 includes bottom tab 173, side wall 149 includes bottom tab 175, side wall 151 includes bottom tab 177, side wall 153 includes bottom tab 179, side wall 155 includes bottom tab 181, and side wall 157 includes bottom tab 183. In this embodiment of the invention, bottom tabs 173 and 183 are contiguous, as are bottom tabs 179 and 181 and bottom tabs 175 and 177, as shown in FIG. 21 , although in other embodiments of the invention, bottom tabs 173 and 183, bottom tabs 175 and 177, and bottom tabs 175 and 177 can be spaced apart from one another.

[0051] The bottom tabs 173, 175, 177, 179, 181, and 183 are configured to receive between them the screw receptacles 23 of the elongated ceiling grid member 21 and the upper portions 24 of the elongated ceiling grid member 22. Specifically, the screw receptacles 23 of the first elongated ceiling grid member 21 are received between the bottom tabs 173 and 175, the upper portions 24 of the elongated ceiling grid member 22 are received between the bottom tabs 177 and 179, and the screw receptacles 23 of the second elongated ceiling grid member 21 are received between the bottom tabs 181 and 183. Receiving these screw receptacles 23 and their upper portions between their respective bottom tabs resists deformation of the receptacles and their upper portions under heavy loads.

[0052] What has been described and illustrated herein are preferred embodiments of the present invention, along with several variations. The terms, descriptions, and drawings are merely for the purpose of illustrating and illustrating those preferred embodiments and are not intended as limitations on the scope of the invention. Those skilled in the art will recognize that many different embodiments and variations beyond those specifically disclosed are within the scope of the present invention, as defined by the following claims.

Claims

1. having a longitudinal axis in a longitudinal direction; a screw member receptacle having (a) a pair of spaced-apart side walls extending parallel to the longitudinal direction and spaced apart in a transverse direction perpendicular to the longitudinal direction, and (b) threaded to threadably receive and retain a first screw member; (a) a vertical wall parallel to the pair of spaced-apart side walls and (b) spaced laterally from the pair of spaced-apart side walls; (a) a first inclined wall extending outward in the lateral direction from one of the pair of spaced-apart side walls and extending downward in a vertical direction perpendicular to the longitudinal direction and the lateral direction, and (b) joined to the vertical wall; (a) a lower portion at a lower end of the vertical wall in the vertical direction, (b) extending inward in the lateral direction from the vertical wall, and (c) configured to support a ceiling tile; A long ceiling grid member comprising:

2. 2. The elongated ceiling grid member of claim 1, wherein the first inclined wall extends in the vertical direction from one of the pair of spaced-apart side walls between an uppermost edge and a lowermost edge of the one of the pair of spaced-apart side walls.

3. 3. The elongated ceiling grid member of claim 2, further comprising: (a) a second inclined wall joined at a first end to one of the pair of spaced-apart side walls below a joint between the first inclined wall and the one of the pair of spaced-apart side walls in the vertical direction; and (b) a second inclined wall joined at a second end to the vertical wall below a joint between the first inclined wall and the vertical wall in the vertical direction.

4. 4. The elongated ceiling grid member of claim 3, wherein the second sloped wall joins the one of the pair of spaced-apart side walls below a lowermost edge of the one of the pair of spaced-apart side walls.

Images