Main Tee Splice Connection With Self-Aligning Spring Steel Clip
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Solution Overview
Problem
Existing suspended ceiling grid systems face challenges with splice connections for main runners, including hard assembly, face misalignment, and inconsistent insertion pressure due to variations in material thickness and tool wear.
Innovation Solution
A splice connection featuring a uniquely formed pocket between the central web of the runner and a separate spring steel clip, which aligns and interlocks with an identical opposed end assembly, ensuring consistent insertion pressure and reliable high-strength joints regardless of material variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an integral splice is formed from the grid runner web material, then the connection can be made with simple structure, but the insertion pressure becomes inconsistent due to material thickness variations
Solution Approach 1:
The splice connection is divided into two separate components: a pocket formed in the grid runner web and a separate tongue member. This segmentation allows the tongue to be made from a different material (steel strip) with controlled dimensions, independent of the grid runner material thickness variations, thereby ensuring consistent insertion pressure while maintaining structural simplicity.
2Reliability
If the pocket and tongue features are formed with fixed geometry, then the connection achieves reliable interlocking, but face misalignment occurs due to material variations
Solution Approach 1:
The tongue member is designed with a localized cam surface featuring specific geometric properties (inclined plane) that provide self-alignment functionality. This local geometric feature compensates for material thickness variations by mechanically guiding the runners into proper face alignment during insertion, while the rest of the connection maintains fixed geometry for reliable interlocking.
3Ease of operation
If the splice uses a lanced pocket and protruding tongue design, then the assembly process becomes simplified, but hard assembly occurs due to geometric variations
Solution Approach 1:
The tongue member is pre-formed with a cam surface that performs the alignment action automatically during insertion. As the tongue is inserted into the pocket, the cam surface engages first and guides the runners into proper alignment before the final locking engagement occurs. This preliminary alignment action reduces insertion force and prevents hard assembly while maintaining the simplicity of the lanced pocket and protruding tongue design.
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 consistent and strong connection with self-alignment capabilities, reducing assembly difficulties and ensuring reliable joint integrity across varying material thicknesses, while allowing for easy disconnection without tools.
Implementation Method 1
the resilient nature of the clip and web assembly
Data Source
Figure 1~9
Figure 2~5
Figure 6~8
AI summary
A main tee with separate clips affixed on its ends for splicing the tee with identical tees in end-to-end butt joints. The tee and clip form a pocket for receiving the projecting end of an opposing clip with a uniform low insertion force. The clip is self-aligning with the pocket and when interconnected the clips precisely align the coupled tees both vertically and horizontally. The clips, formed of relatively strong material, have mutually engageable locking surfaces that ensure a strong joint.