Suspended Ceiling Cross Runner Connector With Wing-Shaped Locking Tab
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Solution Overview
Problem
Existing connectors for cross runners in suspended ceiling systems face challenges in providing reliable and strong connections while mitigating material separation issues, ensuring correct positioning, and maintaining cost-effectiveness.
Innovation Solution
The cross runner is designed with a connector featuring a resilient first tongue and a wing-shaped locking tab that engages with the main runner's opening, along with a top bulb collapse to counteract material separation, enhancing tensile strength and ensuring precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector is formed integral with the cross runner, then manufacturing cost is reduced, but material separation (spread) occurs between the two layers of material in the connector
Solution Approach 1:
The patent applies preliminary anti-action by forming a collapsed portion in the top bulb that creates pre-tension in the central web, which counteracts the spreading force between the two layers of material before the connector is even installed. This pre-applied counter-force prevents material separation during connection operations.
Solution Approach 2:
The patent changes the physical state of the top bulb from an expanded state to a collapsed state, creating a collapsed portion that generates tensile stress in the central web. This parameter change (from expanded to collapsed) transforms the top bulb into a tensioning element that holds the two layers of material together.
2Reliability
If the connector provides strong locking engagement, then connection reliability is improved, but correct positioning of the cross runner becomes difficult
Solution Approach 1:
The patent segments the locking tab into distinct functional zones: a collapsed portion for positioning and alignment, and an engaged portion for secure locking. This segmentation allows each zone to perform its specific function optimally without interfering with the other, achieving both precise positioning and reliable locking.
Solution Approach 2:
The collapsed portion of the locking tab performs preliminary action by making initial contact with the main runner to establish correct positioning and alignment before the engaged portion is forced into the opening to create the secure locking engagement. This sequential action ensures proper positioning precedes strong locking.
3Ease of manufacture
If the connector design is simplified, then manufacturing cost is reduced, but connection strength is compromised
Solution Approach 1:
The patent changes the geometric parameter of the locking tab by collapsing a portion of it, which creates a compact structure that is both simple to manufacture and strong. The collapsed geometry provides structural reinforcement while maintaining manufacturing simplicity, as it can be formed in a single stamping or molding operation.
Solution Approach 2:
The connector utilizes composite action by combining the collapsed portion (for positioning) and the engaged portion (for locking) into a single integrated element. This composite structure achieves both positioning and locking functions without requiring multiple separate components, maintaining simplicity while enhancing strength.
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 provides a robust and reliable connection with improved tensile strength and precise positioning, while mitigating material separation issues, thus enhancing the overall stability and functionality of the suspended ceiling system.
Implementation Method 1
the first tongue is resiliently displaceable in a first lateral direction of the cross runner
Implementation Method 2
the wing shaped locking tab is configured to engage with a side edge portion of the opening of the another runner
Data Source
Figure 1
Figure 2~5
Figure 3~4
AI summary
A cross runner (30) for a grid of profiles of a suspended ceiling system (1), the cross runner (30) being provided with a connector (40) insertable into an opening (12) of another runner (10) of the grid of profiles. The cross runner (30) has central web (33) comprising two layers of material and is provided with a top bulb (31) and two flanges (32) at a bottom portion thereof. The connector (40) is arranged at a first end (34) of the cross runner (30) and comprises a first tongue (41) and at least one additional tongue (42). The first tongue (41) is resiliently displaceable in a first lateral direction (D1) of the cross runner (30) and is provided with a wing shaped locking tab (50) protruding in a opposite second lateral direction (D2) of the cross runner (30). The wing shaped locking tab (50) is configured to engage with a side edge portion (11) of the opening (12) in response to insertion of the connector (40) into the opening (12) such that the first tongue (41) is resiliently displaced in the first lateral direction (D1) in order to allow the wing shaped locking tab (50) to be passed through the opening (12). The wing shaped locking tab (50) has a trailing edge (52) comprising a straight locking section which extends perpendicular to the longitudinal axis (L) of the cross runner. The wing shaped locking tab (50) has a leading edge (51) comprising a straight engagement section which extends at an acute angle (C) to the longitudinal axis (L) of the cross runner (30). The invention also relates to a suspended ceiling system comprising such a cross runner.