Malleable Cross Member for Ceiling Grid Trimming
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Solution Overview
Problem
Conventional narrow channel systems in suspended ceiling grids face difficulties in trimming the ends of utility components like panels and lights, as using short cross runners or tees with conventional end connectors is impractical and costly, and existing solutions often damage the grid system during installation.
Innovation Solution
A cross member made from standard grid tee stock, with integral end connectors that can be field-modified to fit various configurations, including occupied and unoccupied cross tee slots, allowing for easy assembly and connection without special tooling, and featuring malleable sheet metal plies that can be bent or trimmed for secure installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional end connectors are used with short cross runners to trim utility components, then the ends of panels and lights can be trimmed, but the installation becomes impractical and costly
Solution Approach 1:
The patent combines the cross runner body and end connector into a single integrated component. The T-shaped cross member includes perpendicular flanges that directly serve as end connectors, eliminating the need for separate end connector pieces and simplifying the assembly process for trimming utility components.
Solution Approach 2:
The cross member serves multiple functions: it acts as a structural support element, a trimming component for utility hardware, and an integral end connector all in one piece. This multi-functionality reduces the number of parts needed and simplifies installation.
2Adaptability or versatility
If special short cross runners are manufactured to trim channel ends, then trimming functionality is achieved, but special tooling and manufacturing procedures are required
Solution Approach 1:
The patent uses standard grid tee stock with uniform material properties and cross-sectional dimensions throughout. This homogeneous material approach allows the same standard stock to be used for all cross members regardless of position or configuration, eliminating the need for special tooling or manufacturing procedures.
Solution Approach 2:
The cross member is created by cutting standard tee stock into appropriate lengths and configuring the ends. This segmentation of the standard stock into smaller functional units provides adaptability while maintaining ease of manufacture through use of standard materials.
3Reliability
If conventional end connectors are used in occupied cross tee slots, then connection is achieved, but interference with the grid system occurs
Solution Approach 1:
The patent modifies the end connector geometry at specific locations to accommodate occupied slots. The T-shaped flanges can be configured with reduced height or offset positioning at the end areas where they interface with potentially occupied cross tee slots, preventing interference while maintaining connection reliability in unoccupied slots.
Data Source
AI summary
A short cross member for a narrow utility channel formed of malleable sheet metal and having a vertical double ply web and a horizontal flange symmetrically disposed on both sides of a lower edge of the web, integral end connectors formed on each end of the cross member from sheet material contiguous with the web, the integral end connectors being arranged to support the flange in coplanar relation with flanges of the channel, the end connectors and the web being weakened at a predetermined vertical line whereby the cross member can be assembled in a narrow channel by bending at the associated line of weakness to shorten the effective overall length of the cross member.