Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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1 FIELD OF INVENTION
This invention relates -to an improved connection or joint for
members of a grid system used, for example for suspending a sus-
pended ceiling and a process for forming the join-t.
BACKGROUND OF INVENTION
Grid systems for a suspended ceiling are customarily composed
of a plurality of horizontal members intersecting one another at right
angles so as to form a uniform grid. Some of the members or components
~ making up the grid system are usually suspended from vertical hangers
attached to the structural ceiling while some of the peripheral com-
ponents are secured directly to the vertical walls defining the
peripheral extent of the system. Such system is also customarily used
to conveniently support electrical fixtures and wiring~ heating and
air conditioning vents or virtually any other suitable components to
be interposed in the suspended ceiling.
Components of the system usually carry support flanges for sup-
porting ceiling panels or tiles in the grid to present an aestheti-
cally pleasing noise reducing ceiling and separate the room environment
from the space between the structural ceiling and suspended ceiling.
In some instances the panels are sealed to the flanges to seal the
space from one another.
Customarily, the process oF assembling or suspending the hori~ontal
members of a suspended ceiling involves two steps:
- hanging the members from a structural ceiling; and
- connecting the grid members, where they intersect to each other
and to any walls.
Until my invention, the process for connecting the horizontal
members to each other and to a wall, and the actual connection, have
both been relatively complex, not lending to ease of assembly and dis-
assembly. For example, a number of grid systems have been proposed
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1 involving vertical n~tches permitting one member to overlie anot~ermember and be carried in the notches (as shown in for example U.S.
Patents 3,031,042; 3,263,388; 3,001,001; 3,965,632; 3,304,684; and
4,114,327) and slots through the components for receiving connecting
shafts, tabs or tongues extending longitudinally from the ends of other
components positioned at right angles and tabs or connectors overlying
or abutting intersecting members securing them together (as shown in for
example U.S. Patents ~,043,689; 2,286,976, 3,333,387; 3,292,332;
2,888,113; 4,086,480; 3,396,997; 3,305,256; 3,340,662; 3,265~879;
10 3,846,031; 3,185,833; 3,333,387; 3,378,976; 3,275,817 and 2,946,~14).
The drawbacks of these methods are that they, may recuire tools spe-
cifically designed for the system for assembly, do not permit simple or
quick assembly and disassembly, may require the fabrication of addi-
tional connecting parts and may require comparatively detailed machining
of the members to accommodate the various vertical notches, slots or
tabs.
U.S. Patent ~lo. 2,72~,957 discloses moulding strips each carr1ing
a longitudinal channel raving lips extending from the toP and bottom
edges of the channel towards the other lip and a groove to receive the
edg~s of a flat sheet (for example, a counter, table, etc.) above the
longitudinally extending groove. A support is secured in t~e longi-
tudinal channel by sliding it down the lersth sf the channel until in
the desired position.
It is therefore an ob~ect of this invention to provide improved
components suitable for use to form an improved ioint suitable for use
to assemble an improved ceiling grid system and an improved method of
assembling the grid system.
Further and other objects of the invention will be apparent to
those skilled in the art from the following summary of the invention and
detailed description of embodiments thereof.
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1 SUMMARY QF INVENTION
According to one aspect of the invention, an extrusion member is
provided suitable for forming an improved joint comprising a vertically
extending web, at least a pair of flanges spaced from one another and
extending from one side thereof away from the web, one lip extending
from each flange towards the other flange to define a channel between
the lips and web and a support flange carried by one end of the web
extending laterally from the web beyond the width of -the channel.
According to another aspect of the invention the web may carry a
centrally disposed channel having a bed therein, the channel opening in
a direction away from the side o-f the web from which the flanges and
support flange extends. Preferably the channel carries centrally
disposed apertures through the bed at spaced predetermined intervals in
the bottom.
According to another aspect of the invention, the web may have a
pair of flanges spaced from one another extending from the other side of
the web ~preferably aligned with the other flanges), one lip extending
from each such flange towards the other flange and aligned with the lip
on the other flange to define a channel between the lips and web of the
same dimensions as the other channel and a support flange carried by the
web comprising an extension of the support flange on the other side of
the web and extending laterally beyond the width of the channel on the
other side of the web.
Preferably the channels are all of equal width. According to
another aspect of the invention, the flange proximate the support flange
from which flange, the lip extends, and the support flange may coincide
and the lip extends from a position intermediate the width of the flange
towards the other flange.
According to another aspect of the invention, the support flange
may carry a depression or trough along its length intermediate that
1 portion laterally beyond the lateral extent of the channel and outer
edge of the support flange.
According to another aspect of the invention, an extrusion member
is provided comprising a vertically extending web, a pair o-f colinear
flanges extending laterally from one end of the web from either side,
each flange carrying a lip upstanding from a position intermediate its
outer edge and the web to define a pair of like channels, and a pair of
colinear laterally extending flanges extending from the web spaced -from
the other flanges and carrying a pair of lips aligned with, and directed
towards, the other lips to define a pair of channels having the same
dimensions as the other channels, the colinear flanges extending laterally
from one end of the web~ Preferably spaced apertures are provided along
the length of the web.
According to another aspect of the invention~ the extrusion member
having flanges extending from both sides of the web, may have its end
modified to present a longitudinally extending web having a leading edge
and of material of a width greater than the space between the lips of
the pair of opposed spaced flanges but less than the distance between
the bottoms o-f the opposed channels, each such web carrying (i) a
centrally disposed projection (locating pin) extending longitudinally
from the leading edge of the web away from the web, and (ii) a pair of
aligned notches in the web, one in each side edge of the web to ac-
commodate a lip of each pair of opposed lips defining the opposed
channels, each notch being spaced from the leading edge by a distance
equal to the width of the channel it must accommodate when the lip
defining the extent of the channel is carried in the notch, the portion
of each web extending from the modified end of the extrusion member not
carrying any flange portion therebelow for a distance from the leading
edge of the modified end of the extrusion member equal to the width of
the support flange of another member to which it will be secured.
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1 According to another aspect of the invention -the ex-trusion member
may itself be modified to carry such modification.
According to another aspect of the invention, the extrusion member
may carry a separate member which provides such modification as for
example by being fastened to the web of the extruded member as by screws,
the modification comprising a web having a leading edge and a width
greater than the distance between opposed lips but less than the width
between the distance between the bottoms of opposed channels, the
modification carrying a pair of no-tches in its side edges to receive the
opposed lips and each notch spaced from the leading edge by a dis-tance
to accommodate the channel proximate the lip to be carried by the notch,
and the leading edge carrying a projection (locating pin) extending
longitudinally of the plane of the web away -from the web.
Therefore, according to another aspect of the inven-tion, by connec-ting
these components by inserting -the projections on the leading edges of
the modified portions oF the extrusions into the apertures of other
members previously suspended from -~he structural ceiling and by inserting
the lips into the respective notches3 a grid for supporting ceiling tile
can be created as required. For ease of assembly, this invention provides
a novel process for connecting the members. In this regard, when a pair
of members are disposed with the place of the webs of the members ma-terially
angled to one another so that there is a horizontal component to such
angular disposition, and the projection (locating pin) on the leading
edge of the web of one modified extrusion member is inserted through an
aperture in the web of another extrusion member (whether through the
aperture in web or channel carried by the web), and the plane of the
web, rotated, the lips become lodged in the notches locking the members
together in a predetermined position. Therefore, according to another
aspect of the invention, a process for connecting two members is pro-
vided, one member carrying a web having two sides and a leading edge, a
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1 projection carr-ied by the leading edge of the web, a pair of notches
opening through both sides, one -through each side, and spaced from the
leading edge by a predetermined distance, the other member comprising
a web, a pair of flanges extending from one side of the web and spaced
from one another by a distance at least equal to the width of the web of
the first member, each of the flanges carrying a lip extending towards
the other flange by a distance equal to the depth of the notch and
defining a channel with the web opening towards the other flange of a
width to permit the notch to receive the corresponding lip when the
0 members are secured together~ -the web having an aperture therein for
receiving the projection, the process comprising the steps of:
(1) bringing the members together with the plane of the webs
angled vertically with respect to one another;
(2) inserting -the projection of one member through the aperture of
the other;
(3) rotating at least one of the members to position the planes
of the webs to extend vertically parallel to one another
whereby the notches receive the lips thereby locking the two
members together.
Thus the joint formed comprises the projection on the one member
extending through the aperture through the web of the other member and
the notches of the one member receiving the lips of the other member. ~y
assembling the various components as described a grid system of the
components is assembled. 3y securing the tiles on the Flanges with glue
carried in the depressions or troughs in the flanges, the ceiling tiles
can be permanently secured to the members until the bond is destroyed.
The extruded members, preferably comprise aluminum (best for commercial
purposes) or plastics material (for residential purposes, where strength
may not be as important). Therefore by using the components of the
invention to form a grid, a ceiling that is impervious to the migration
1 o-f dust, air or corrosive contaminants, From either above or below the
ceiling may be provided by utilizing support flanges of -the extruded
member carrying the recess or depression for carrying a sealant between
the support flange and overlying ceiling panels. This is useful wherever
particularly clean or sterile room environments are required. For
example, in food processing plants it is common for the ambient environ-
ment to expose the ceiling to chlorine, salt, excessive humidity in the
air and temperatures of 40 -to 50 degrees F making a corrosive environment.
In such an environment the ceiling tile overlies and forms a seal ~ith
the lip of the supporting flange to seal the room -from the infiltration
of conta~inants originating above the ceiling. Because this environment
necessitates the dismantling of the ceiling and washing the ceiling
tiles and supporting extrusion members from time to time9 the use of
extrusion members made of aluminum are ideally suited for this appli-
cation.BRIEF DESCRIPTION_OF _HE DRAWINGS
The invention will now be illustrated with reference to -the following
drawings:
Figure 1 is a perspective view of an unmodified extrusion member
illustrating a modification that may be made to the member (shown dotted)
for use according to one embodiment of the invention.
Figure 2 is a side view of the unmodified extrusion member and the
proposed modifications shown if Figure 1 (dotted).
Figure 3 is a perspective view of modified extrusion members according
to an embodiment of the invention and illustrates a method of forming a
connection therebetween.
Figure 4 is a perspective view of a portion of a grid system formed
by connecting the modified extrusion members o-f Figure 3.
Figure 4A is a perspective view of a portion of the grid system
formed by connecting an unmodified extrusion member carrying flanges
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1 either side of the web shown in Figure l, with a modi-fied extrusion member
carrying flanges either side of the web shown in Figure 3.
Figure 5 is a side view of -the connection shown in Figure 4;
Figure 6 is a side view of a similar connection as in Figure 5
comprising modified extrusion members according to another embodiment of
the invention.
Figure 7 is a perspective view of a portion of a grid system formed
by connecting the modified extrusion members shown in Figure 6, according
to another embodiment of the invention.
Figures 8 and 9 are perspective views illustrating the forma-tion of
the connection between the components shown in Figure 7.
Figure 10 is a schematic view o-f the formation of a modified extrusion
member according to an embodiment o-f the invention.
Figure 11 is a cross-sectional view taken along the line 11-11 in
Figure 7 looking in the direction of -the arrows.
DETAILED DESCRIPTION OF EMBODI~ENTS OF THE INVENTION
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With reference to Figure 1 there is shown an extrusion member 12 of
aluminum comprising a vertically extending web 14 having a pair of
colinear laterally extending flanges 16 proximate the top 17 of web 14
and a pair of colinear laterally extending support flanges 18 at the
bottom 19 of web 14. Each of flanges 16 are of equal width as are
flanges 18. Each of flanges 16 carries a vertically downwardly extending
lip 20 of its side edge. Each support flange 18 carries a vertically
upwardly extending lip 24, a predetermined distance from web 14. Each
support flange 18 also carries a longitudinally extending depression or
recess 26 intermediate lip 24 and the outer side edge 28 of flange 18.
Lips 20 and 24 and web 14 together present U-shaped longitudinal channels
32, 34, 36, 38 respectively having as their bottoms, flanges 16 and 18,
as the case may be.
With reference to Figures 1 and 2, extrusion member 12 may be
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1 modified by the removal o-F material along the do-tted line to present web
portion 44 extending from one end of the extrusion 12 by the removal of
portions of flanges 16 and 18, lips 20 and 24, and web 14. The resultant
"exposed" vertical web portion 44 or "key" therefore carries notches 48
and 50 a prede-termined distance from the leading edge 54 of web portion
44. A projection or locating pin 56 is carried on the leading edge 54.
Web portion 44 is of the same width in all extrusions as the width of
web 14 between flanges 16 and 18.
With reference to Figure 3, "key" 44 of member 12 is designed to
secure member 12 to another member 12'. Member 12' comprises modified
central web 44' carrying laterally opening channel 45 having bed 45'
having a pair of longitudinally extending channels 34', 38' defined by
flanges 16' and 18', web 44' and lips 20' and 24', lips 20' and 24'
spread over from web 44' and particularly portion 45' by a dis-tance
equal to the distance between leading edge 54 and notches 48 and with
each notch 48 and 50 being of a size to secure lips 20' and 24' therein.
As will be seen in Figure 3, the two components may be joined by
inserting projection 56 into aperture 56' through bed 45' with both webs
angled out of vertical alignment with one another as shown and by rotating
the extrusions to bring both webs into a position to extend vertically
the notches 48 and 50 and receive and secure lips 20' and 24'.
The reader will note that web portion 44' has a greater portion of
flange 18 removed from its side edge than flange 16. This is to permit
flange 18 of member 12 to abut flange 18' of extrusion member 12' when
the two are secured together.
For the purposes of assembling a grid system, extrusion member 12'
is anchored to the wall by screws 64 (see Figure 4) and members 12 are
secured to it. Other members 12 are then mounted utilizing the aper-
tures 56' in web 14 of members 12 as shown in Figure 4. Because ex-
trusion 12' is mounted against wall 60, web 44' of extrusion 12' carries
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1 laterally opening channel 62 opening away from -flanges 16' ancl 18'.
Apertures 56' extending -through portion 45' are spaced From wall 60 to
receive projection 56 extending through aperture 56' and permit any
portion of projection 56 extending past bed 45' of channel 45 to be
accomodated. (see Figure 5). The other end of member 12 is secured to
for example another member 12' in like manner. Intermediate the length
of member 12, other transverse members 12 are secured to member 12 in
the manner shown in Figure 4, to continue to erect the grid system.
Cnce the grid system is erected, tile 65 is positioned on flanges 18 and
18' and secured by sealant carried in depressions 26 and 26' to the
members 12 and 12'.
With reference to Figure 4A, extrusion member 13' comprises an
unmodified extrusion member as shown in Figure 1 and extrusion member 12
comprises a modified extrusion member. Because extrusion member 13' is
not adapted to be anchored to the wall, but rather is adapted to form a
connection intermediate the length o-f extrusion member 12, i-t carries a
pair of colinear laterally extending flanges 16, 18. Mod;fied extrusion
members 12 are secured to member 13' to continue to erect the grid
system.
W;th reference to Figures 6 through 11 inclusive, the extrusion of
Figure 1 has not been modified to provide the desired profile 44 by the
removal of portions of the web 14 or flanges 16 and 18. Rather an
insert or "modular key" 67 has been provided for securing to web 14 of
member 12 by screws 69 to permit key 16 to act in the same manner as the
25 modified portion 44. Particularly insert 67 comprises web 44 to be
accommodated between flanges 16 and 18 in channels 34 and 38 or 32 and
36. (see Figure 10). I~!eb 44 carries no-tches 68 and 70 on the top and
bottom, and projection or locking pin 72 extending longitudinally from
the leading edge 73 of modular key 67. Modular key is connected to an
30 extrusion member 12 by screws 69 to extend from member 12 by a distance
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1 equal to the width of flange 18' or 18 to permit flange 18 and 18' or 18
and 18' to abut when the members are secured together. As is apparent
from Figures 6 to 11 inclusive, once key 67 is secured to extrusion
member 12, the modified member is secured to another extrusion 12, 12'
or 13' in the same manner as member 12. (See Figures 8, 9 and 7).
As many changes can be made to the embodiments without departing
from the scope of the invention, it is intended that all matter contained
herein be interpreted as illustrative of the invention and not in a
limiting sense.
