Suspended Ceiling Grid Runner with Reinforced End Connector
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Solution Overview
Problem
Reducing the manufacturing costs of suspended ceiling grid members while maintaining their structural integrity, as thinner sheet materials compromise the grid system's strength if not properly addressed.
Innovation Solution
A main runner with a reduced sheet material thickness featuring integrally-formed end connectors, staggered stitches for web layer security, a hemmed flange design, and a modified reinforcing bulb with increased height and rounded corners, allowing for efficient end-to-end connections and enhanced structural resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the thickness of the sheet material is reduced to lower manufacturing costs, then material cost decreases, but the structural integrity of the ceiling grid system is compromised
Solution Approach 1:
The end connector is segmented into multiple functional components: a body portion, a folded-back strap, and locking tabs. This segmentation allows each component to perform a specific function (connection, reinforcement, locking) that collectively compensates for the reduced material thickness, maintaining structural integrity while using thinner material.
Solution Approach 2:
The connector transitions from a planar configuration to a three-dimensional structure through folding the strap back parallel to the web and positioning locking tabs in spaced relationships. This dimensional transformation creates multiple engagement points and structural layers that compensate for reduced material thickness, providing adequate strength with thinner sheet material.
2Weight of moving object
If the thickness of the sheet material is reduced, then the weight of each runner decreases making it easier to handle, but the structural characteristics of the grid system are compromised
Solution Approach 1:
The connector design concentrates material and structural complexity at critical locations (the end connector region with its folded strap and locking tabs) while allowing the main runner body to use thinner material. This localized reinforcement maintains overall structural reliability while reducing the weight of the entire runner assembly.
Solution Approach 2:
The connector forms a composite structure through the folded strap and locking tabs that create multiple layers and engagement points. This composite configuration provides enhanced structural performance at the connection points, compensating for the thinner material used in the main runner body, thus maintaining reliability while reducing weight.
3Ease of manufacture
If the sheet material thickness is reduced, then manufacturing cost decreases, but the ability to maintain structural resistance decreases
Solution Approach 1:
The connector is designed with pre-formed geometric features (folded strap, locking tabs, camming surfaces) that are integrated into the roll-forming process. These preliminary structural configurations are built-in during manufacturing, providing structural resistance without requiring additional material thickness or post-manufacturing assembly steps, thus maintaining ease of manufacture while ensuring adequate force resistance.
Solution Approach 2:
The connector incorporates curved and folded geometries (folded-back strap, rounded engagement surfaces) that distribute stresses more effectively than flat configurations. These curved features enhance structural resistance by creating more efficient load paths, allowing thinner material to withstand the required forces.
Data Source
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AI summary
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.