Suspended Ceiling Grid with Integrated Runners
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Solution Overview
Problem
The installation of suspended ceiling systems with non-conventional shapes, such as curved grids, faces challenges in maintaining accurate alignment of grid elements, leading to increased time and cost in assembly.
Innovation Solution
A suspended ceiling system featuring primary carriers with notches for main runners, splice connectors for length extension, and hanger clips for wire attachment, which facilitates accurate spacing and quick assembly by eliminating the need for cross-tees and allowing for self-centering of hanger wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a curved suspended ceiling grid system is installed, then the ceiling can define complex spaces and add architectural interest, but the alignment of grid elements becomes difficult and assembly time increases
Solution Approach 1:
The grid system is divided into modular components: curved main runners with integrated cross-runners, primary carriers with notches, and splice connectors. These segmented elements can be assembled independently and quickly, reducing overall assembly time while maintaining the ability to create complex curved ceiling shapes.
Solution Approach 2:
The cross-runner is merged with the main runner as a single integrated component rather than separate pieces. This integration ensures accurate alignment of grid elements and eliminates the need for separate alignment procedures, directly reducing assembly time while maintaining structural integrity of the curved ceiling grid.
2Adaptability or versatility
If a curved suspended ceiling grid system is installed, then the ceiling can define complex spaces, but the alignment accuracy of grid elements deteriorates
Solution Approach 1:
The cross-runner is merged with the main runner as a single integrated component. This integration ensures that the grid elements maintain accurate alignment throughout the curved structure, as the cross-runner is pre-positioned relative to the main runner during manufacturing, eliminating alignment errors that would occur with separate components.
Solution Approach 2:
The primary carrier with its notch acts as an intermediary element between the curved main runner and the ceiling panel. The notch in the primary carrier precisely receives the main runner, ensuring accurate spacing and alignment of grid elements along the curved ceiling structure.
3Ease of manufacture
If traditional grid assembly methods are used, then standard ceilings can be installed, but curved ceilings require increased time and cost
Solution Approach 1:
The grid system uses segmented modular components including curved main runners with integrated cross-runners, primary carriers with notches, and splice connectors. These standardized segments can be manufactured efficiently and assembled quickly, maintaining productivity for curved ceilings while keeping manufacturing straightforward for standard ceilings.
Solution Approach 2:
The curved main runner with integrated cross-runner serves multiple functions: it provides structural support, defines the curved geometry, and incorporates alignment features for ceiling panels. This multi-functionality eliminates the need for separate components, increasing assembly efficiency for curved ceilings without complicating standard ceiling installation.
Data Source
AI summary
A grid system is provided that is particularly suited for the suspended ceiling system that varies in the vertical plane. An elongated carrier tube is provided the spans substantially the width of the grid system that has a slot therein adapted to receive the strengthening bulb of a main runner. A clip is provided that seats on the carrier tube that has opposed faces for capturing the bulb of the runner, so as to secure the runner to the tube carrier.