Suspended Ceiling Cross Runner Connector With Offset Guide-Lip Locking

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Solution Overview

Problem

Existing cross runner connectors for suspended ceiling systems face challenges in providing reliable locking while allowing easy disconnection, ensuring correct positioning, and maintaining cost-effectiveness, often resulting in high manufacturing costs and dimensional errors due to interlocking mechanisms.

Innovation Solution

A cross runner connector design featuring a guiding lip and a locking lip separated by a slit, with a guide edge portion and a distal guide tip offset for lateral displacement during insertion, allowing for reliable locking and easy disconnection by twisting, and minimizing material usage by eliminating the need for additional interlocking components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a cross runner connector provides reliable locking through resilient lips, then connection reliability is improved, but disconnection becomes difficult

Engineering Contradiction:

Improvelocking reliabilityVSAvoiddisconnection ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connector transitions from a static resilient lip design to a dynamic system where the guide tip's lateral offset creates a displacement path. During disconnection, the connector can be laterally moved to disengage the locking protrusion from the engagement edge, transforming the locking mechanism from permanently resilient to temporarily locked with easy release through lateral motion.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The guide tip acts as an intermediary element between the connector body and the opening. Its lateral offset creates a mediator path that allows the locking protrusion to engage and disengage from the engagement edge through lateral displacement, bridging the contradiction between secure locking and easy release.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If a cross runner connector ensures correct positioning through multiple engagement features, then positioning precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvepositioning precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The guide edge portion serves multiple functions: it guides the connector into the opening, provides a lateral displacement path for the guide tip, and works with the opening notch to ensure correct positioning. By making this single feature multi-functional, the design achieves precise positioning without adding multiple separate engagement features that would increase manufacturing complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The guiding and positioning functions are merged into the guide edge portion and opening notch combination. Instead of separate guiding features and positioning features, the design combines these functions into an integrated system where the guide edge's lateral offset and the opening notch work together to achieve both guidance and precise positioning, reducing the number of parts and manufacturing steps.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If cross runners are connected from opposing sides with interlocking mechanisms, then connection stability is improved, but dimensional errors accumulate

Engineering Contradiction:

Improveconnection stabilityVSAvoiddimensional accuracy

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The interlocking mechanism between cross runners is extracted and replaced with independent connection to the main runner. Each cross runner connector connects independently to the main runner's opening without interlocking with opposite-side connectors, eliminating the cumulative dimensional errors while maintaining connection stability through the main runner's engagement edges.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of having cross runners interlock with each other, each connector independently copies the connection geometry from the main runner's opening. The first and second engagement edges of the opening provide identical reference surfaces for connectors from opposite sides, ensuring consistent positioning without dimensional accumulation.

Inventive Principle:

Principle #26Copying

4Reliability

If a cross runner connector uses traditional resilient lips for engagement, then connection reliability is improved, but material usage increases

Engineering Contradiction:

Improveengagement reliabilityVSAvoidmaterial usage

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The design uses a thin flexible guide tip with lateral offset instead of thick resilient lips. The guide tip's flexibility allows it to laterally displace during insertion and engagement, providing reliable connection through elastic deformation of a thin element rather than requiring substantial material for resilient lips, thus reducing material usage while maintaining engagement reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution ensures a reliable and cost-effective connection and disconnection mechanism with improved material utilization, preventing dimensional errors and providing feedback through a snap or click for secure locking, while allowing independent connection of cross runners from opposing sides without interlocking issues.

Implementation Method 1

the guide edge portion positioned in the opening notch of the opening, and the distal guide tip being offset in a first lateral direction such that the cross runner connector is laterally displaceable in the first lateral direction in response to insertion of the cross runner connector into the opening of the main runner

Methodology Applied

Scientific EffectGeometric guidance: Geometry

Implementation Method 2

the locking lip having a locking protrusion protruding in the first lateral direction

Methodology Applied

Scientific EffectMechanical engagement: Mechanical Fastener

Implementation Method 3

an insertion stop for defining a locking position in the longitudinal direction of the cross runner connector

Methodology Applied

Scientific EffectGeometric constraint: Geometry

Data Source

PatentEP3246482B1Cross runner connector, main runner and cross runner connector arrangement for a suspended ceiling system

Publication Date: 2022.02.02 SAINT GOBAIN ECOPHON

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AI summary

A cross runner connector for a suspended ceiling system (1) comprising a main runner (10) and a cross runner (30), the cross runner connector comprising a guiding lip (41) and a locking lip (42) separated by a slit (43) and extending in the longitudinal direction (P2) of the cross runner connector. The guiding lip (41) has a guide edge portion (44) provided with a guide lip notch (45) and a distal guide tip (46) being offset in a first lateral direction (P3), and the locking lip (42) has a locking protrusion (48) protruding in the first lateral direction (P3). The cross runner connector further comprises an insertion stop (50) for defining a locking position in the longitudinal direction (P2) of the cross runner connector. The invention further relates to a main runner for a suspended ceiling system and a cross runner connector arrangement comprising the cross runner connector and the main runner.