US3374596A - Suspended ceiling system - Google Patents

Description

March 26, 1968 o' ET AL 3,374,596

SUSPENDED CEILING SYSTEM 3Sheets-Sheet 1 Filed May l7, 1965 INVENTORS Games A. O'BRIEN I ocHA-ows| a ,m/A,4

Games A 53.

March 26, 1968 e. A. OBRIEN ET AL 3,374,596

SUSPENDED CEILING SYSTEM 3 Sheets-Sheet 2 Filed May 17, 1965 IN vEN'roRs Geoacaa A. OBmerv Geese: A. kocmmwsxl n flqgmwg/afwaw A-r'rYs.

March 26, 1968 G. A. OBRIEN ET AL 3,374,596

SUSPENDED CEILING SYSTEM Filed May l7, 1965 3 Sheets-Sheet ZS lwvzm'ozs 2 Gsoase A.O'BRIEN Gaoaes A. KOCHANOWSKI WaL Lflwl A-n-vs,

United States Patent 0 3,374,596 SUSPENDED CEILING SYSTEM George A. OBrien and George A. Kochanowski, Chicago, Ill., assignors to Kinkead Industries Incorporated, Chicago, 11]., a corporation of Illinois Filed May 17, 1965, Ser. No. 456,227 7 Claims. (Cl. 52-664) ABSTRACT 0F THE DISCLOSURE An improved frame structure for use in a grid for a suspended ceiling system in which each frame member is provided with a locking tongue projecting from one end of the member and having an aperture near the end of the tongue for forming a vertical locking surface facing rearwardly of the leading edge of the tongue. A pair of opposed longitudinal, vertically spaced tabs project from the vertical fin of the adjacent frame member so as to deline a channelfor receiving the tongue and holding the tongue firmly against one side of the vertical fin. The tabs are formed from the vertical fin, such as by stamping operation, with the opposed longitudinal edges of the tabs being spaced apart to form a divider web therebetween. One end of the divider web is cut away from the vertical fin so as to form a longitudinal tang between the tabs with an end portion of the tang being bent out of the plane of the tin so as to be biased against the tongue inserted between the tabs. The end of the tang engages the vertical locking surface formed by the aperture in the end portion of the tongue so as to lock the tongue longitudinally and prevent retraction thereof from between the tabs. The entrance end of each of the tabs is beveled longitudinally so as to form a V-shaped mouth for facilitating insertion of the tongue and at the same time strengthening the base portion of the locking and biasing tang.

The present invention relates generally to improve ments in a suspension system for receiving and supporting ceiling panels and, more particularly, to an improved interlocking means for connecting the various frame members used in such a suspension system.

Heretofore, a wide variety of different suspended ceiling grids have been proposed. In general, such grid structures consist of wall members, of L-shaped cross section, which are fastened to the wall to form the periphery of the grid; main runners, of inverted T-shaped cross section, which extend parallel to each other between one pair of opposed wall members; and cross members, also of inverted T-shaped cross section, which extend between adjacent main runners. Of course, it is necessary to connect the main runners to cross members in order to provide a rigid supporting frame for the ceiling panels to be inserted therein, and a number of different interlocking means have been proposed for connecting such members. In addition, it is often desirable to form the main runners from a plurality of different sections, so that additional interlocking means must be provided to join the various runner sections.

It is a primary object of the present invention to provide an improved interlocking means which can be used to connect main runners to cross members, and also to connect main runner sections to each other. More particularly, it is an object of this invention to provide such improved interlocking means which is simple and economical to manufacture, simple to assemble, and which holds all the interlocked members firmly in place once they have been assembled. Further, it is an object of the invention to provide such an improved interlocking means which reduces the number of manufacturing steps involved, and yet forms a ceiling grid which is even more rigid and uniform than many of the structures proposed heretofore.

A related object of this invention is to provide such an interlocking means which provides a positive locking action which cannot be released by simply drawing the connected members apart.

It is another object of the present invention to provide an improved interlocking means of the foregoing type in which all the main run-ner sections, wall members, and cross members are of respective universal structure, so that only three different parts need be manufactured for any desired grid structure.

A further object of the invention is to provide an improved interlocking means of the type described which inherently provides alignment of the various members being connected, and also holds such members rigidly in such aligned position so that the desired flush fitting is maintained throughout extended periods of use.

Other objects and advantages of the invention will become apparent upon reading the attached detailed description and upon reference to the drawings, in which:

FIGURE 1 is a perspective of a portion of a suspended ceiling constructed in accordance with the present inven-.

tion;

FIG. 2 is a side elevation of a main runner embodying the improved interlocking means of this invention;

FIG. 3 is a side elevation of a cross member adapted for interlocking connection with the main runner of FIG. 2;

FIG. 4 is a top plan view of the cross member of FIG. 3;

FIG. 5 is a side elevation of a wall member;

FIG. 6 is a fragmentary section taken along line 6-6 in FIGURE 1 passing through one of the joints between abutting main runner sections;

FIG. 7 is an enlarged fragmentary perspective of the interlocked end portions of a pair of abutting main runner sections;

FIG. 8 is a perspective view of the two members shown in FIG. 7 prior to the assembly thereof;

FIG. 9 is a section taken along line 9-9 in FIG. 7 to show the interlocking connection;

FIG. 10 is a vertical section taken along line 1010 in FIG. 8 to show the cross sectional shape of the projecting tabs formed on the main runner section;

FIG. 11 is a vertical section taken along line 1111 in FIG. 8 to show the cross sectional shape of the detent locking member formed in the main runner section;

FIG. 12 is a vertical section of one of the wall members;

FIG. 13 is an enlarged perspective of one of the interlocking connections between a main runner section and a pair of abutting cross members;

FIG. 14 is an exploded view of the members shown in FIG. 13;

FIG. 15 is a section taken along line 15-15 in FIG. 13 to show the interlocking connections between the two cross members and the main runner section.

While the invention is susceptible of various modifications and alternative constructions, certain illustrative embodiments have been shown in the drawings and will be described below in detail. It should be understood however, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the intention is to cover all modifications, methods, alternative constructions, and equivalents falling within the spirit and scope of the invention as expressed in the appended claims.

Referring to the drawings, a suspended ceiling structure embodying the present invention includes a plurality of ceiling panels 10* supported within a suspended grid comprising wall members 11, main runners 12, and cross members 13. The entire grid is suspended from the ceiling 14 by means of plurality of vertical wires which are looped through spaced holes 15a which are formed in the main runners 12. The periphery of the suspended grid is formed by the plurality of wall members 11 which are of L-shaped cross section with the vertical leg of the L being fitted against the sidewall and the horizontal leg extending outwardly from the wall for supporting the main runners 12 or cross members 13 resting thereon. For the purpose of fastening the wall members to the sidewalls, a plurality of spaced holes 16 are formed in the Wall members to receivenails 17 or other fastening elements which are driven into the building wall.

In accordance with one aspect of this invention, the wall member 11 is provided with a projecting longitudinal bead 1-8 on the upper edge of the outer surface of the vertical leg thereof, and a longitudinal groove 19 is formed in the inner surface of the vertical leg. Consequently, as the member 11 is driven in against the wall by the fastening element 17, the bead 18 causes the upper portion thereof above the longitudinal groove 19 to be bent away from the wall so as to urge the lower portion of the member 11 below the groove 19 firmly against the .wall. This insures a snug fit between the exposed lower portion of the member 11 and the building wall to which it is attached, thereby providing a pleasin appearance and also'sealing against the leakage of dirt and the like into the space above the suspended ceiling.

The main runners 12 and the cross members 13 are all of inverted T-shaped in cross section so as to form a vertical fin 20 or 21 extending upwardly from a pair of horizontal flanges 22 or 23. These members may be formed by any suitable method, such as by extrusion for example, and the main runners 12 are preferably provided with a reinforcing bead 24 along the upper edge to improve the strength and rigidity of the members.

Holes 15a are formed at spaced points in the vertical fin 20 of each main runner 12 for the purpose of receiving the hanger wires 15.

In accordance with one important aspect of this invention, the main runners 12 and the cross members 13 are connectedby improvedinterlocking means compris ing a locking tongue projecting from the end of one member and having a substantially vertical locking surface facing rearwardly of the leading edge of the tongue; a pair of opposed longitudinal, vertically spaced tabs projecting from the vertical fin so as to define a channel for receiving the tongue and holding the same firmly against one side of the vertical fin; and a longitudinal tang formed from the vertical fin between the'tabs with an end portion of the tang being bent out of the plane of the fin so as to be biased against the tongue as it is inserted between the tabs, the end of said tang being adapted to engage the vertical locking surface on the locking tongue so as to prevent retraction of the tongue from between the tabs. Thus, referring to FIGURES 7 through 11, a pair of abutting main runner sections 12a and12b are provided with cooperating locking tongues and corresponding pairs of tabs 31. More particularly, the runner section 12b is provided with a longitudinally extending locking tongue 30b which is bent out of the plane of the vertical -fin 2012 so as to fit flush along the surface of the vertical fin 26a of the abutting runner section 12a. The tongue 30b is received between a pair of opposed longitudinal, vertically spaced tabs 31a which may be stamped out of the vertical fin 20a.

In order to hold the tongues 30 in fixed vertical positions, the base portions 32 of each pair of opposed tabs 31 are spaced apart by a distance substantially equal to the width of the locking tongue 30 inserted therebetween. Similarly, for the purpose of holding the tongue 30 in a fixed horizontal position against the surface of the vertical fin to which it is to be connected, the base portions 32 extend outwardly away from the plane of the fin by a distance substantially equal to the thickness be connected. Since the locking tongue is held rigidly 7 against any vertical displacement, the horizontal flanges 22 of the abutting runner sections are maintained flush with each other 'so as to provide a pleasing appearance and to seal against the leakage of dirt and the like between the abutting flanges.

For the purpose of holding the abutting runner sec S tions tightly together in the longitudinal direction, each locking tongue is provided with a substantially vertical locking surface adapted to snap over the end of an out wardly biased tangformed in the opposed vertical fin 20 engaged by each tongue. Consequently, the engage ment of the tang end with the locking surface on the tongue locks the tongue firmly in position so that it can not be retracted from between the channel-forming tabs 31.

Thus, in' the illustrative embodiment, each tongue 30 is provided with a square aperture so that the leading edge of the aperture forms a substantially vertical lock ing surface 35 facing rearwardly of the leading edge 36 of each tongue. As the tongue 30 is advanced between its receiving tabs 31, the locking surface 35 snaps over the end of a tang 37 stamped out of the vertical fin 20. The tang 37 may be conveniently formed from the residual divider web remaining between the opposed longitudinal edges of the tabs 31 so that both the tabs 31 and the tang 37 may be formed in a single stamping operation.

The end portion 38 of each tang 37 is bent out of the plane of the fin 20 so as to be biased against the inner surface of the tongue 30 as it is inserted between the tabs 31. Since the tongue 30 is held firmly against the surface of the fin 20 by the restraining tabs 31, it depresses the tang 37 into the plane of the fin 20 until the vertical locking surface 35 has cleared the leading edge of the tang 37, at which time the bias on the tang causes it to snap into the aperture 35 with the leading edge 38 of the tang bear ing against the tongue locking surface 35. A5 a result, any force which tends to retract the tongue 30 from be-' tween the tabs 31 is resisted by the tang 37. It will be appreciated that any force which tends to retract the tongue 30 will be transmitted longitudinally through the 7 tang 37 into the plane of the vertical fin 20. Consequently, the resistive force offered by this positive locking arrangement is backed up not only by the tang 37, but also by V the entire member 12 from which the tang is formed, so that there is practically no opportunity for disengagement p of the locking arrangement during normal usage. In order receiving tabs 31 and into a locked position, the entrance end of each tab 31 is beveled longitudinally, as indicated 7 at 39, toward the longitudinal edge of the opposed tab so as to form a V-shaped mouth for receiving the tongue;

Moreover, the tang 37 includes a recess 40 in the outwardly'biased end portion 38 thereof to reduce friction 'between the tang and the advancing tongue 30. In addition, the vertical fin 20 is also provided with a recess 41 adjacent the outermost end of the tang 37 to facilitate depression of the tang 37 by the advancing ton-gue 30 until the locking surface 35 has cleared the end of the tang.

In accordance with one feature of the invention, the beveled edges 39 on the tabs 31 are formed at the time the tabs 31 are stamped from the fin so as to form a relatively wide base portion 42 for each tang 37. This base portion 42, which is integral with the vertical fin 20, serves to strengthen the tang 37 and also distributes any forces transmitted through the tang 37 over a greater area of the vertical fin 20.

It should be noted that the end portion 33 of each tang 37 is preferably made slightly narrower than the vertical dimension of the tongue aperture 34 so that the tang 37 is free to snap quickly into place as the tongue is advanced thereover. This insures that the snapping action will be quick and sure so that the positive locking action is practically instantaneous with practically no opportunity for inadvertent disengagement of the two members being connected.

In order to maximize the locking action achieved at each joint in the ceiling grid, it is preferred to form a locking tongue and holding tabs on each of the two abutting runner sections so that the interlocking mechanism is duplicated on the two sides of the mating fins 20a and 20b. Thus, the locking tongue 30a cooperates with holding tabs 31b and locking tang 37b in the same manner described above for elements 305, 31a and 37a. This duplication of the positive interlocking action also offers the further advantage of making the runner section of a more universal nature, i.e., the runner sections may be assembled quickly and efficiently without the necessity for any preliminary orientation thereof to be sure that the tongues are extending in the right direction. The runner sections are completely interchangeable so that only one type of section need be manufactured.

The interlocking connection between a pair of cross T-members 13a and 13b and one of the runner sections 12 is illustrated in FIGURES 13 through 15. It will be noted that the interlocking tongue, tab, and tang arrangement is similar to that described above for the abutting runner sections except that the tongues on the cross T-members are bent at right angles to the planes of the vertical cross fins 21. Also, the end portion of each vertical fin 21 extends beyond the horizontal flanges 23, a distance substantially equal to the width of one of the horizontal flanges 22 on the runner section so that the lower surfaces of the runner sections and cross Ts are flush with each other, while the right angle tongues 50 fit flush against the surfaces of the runner fins 20.

In accordance with a further aspect of this invention, the cross T-tongues 50 are seated firmly against the holding tabs 51 on the runner sections by means of a shoulder seating arrangement. Thus, in FIGURES 13 through 15, the locking tongue 50a is provided with a base portion 55 forming a shoulder 57 which is adapted to fit firmly against the entrance end of the lower tab 51. This serves to stop the tongue 50a in exactly the desired transverse position, with the end of the tang 37 bearing against the locking surface 35, and also serves to resist tilting of the cross T as permitted by any tolerances within the receiving tabs 31. If desired, a second shoulder may be formed at the upper edge of the tongue 50 to bear against the entrance end of the other tab 31. It will be appreciated that the seating shoulders 57 can be formed simultaneously with the tongues 56 in a single stamping operation so that the manufacture of such elements is relatively simple and economical, even though the resulting structure is superior in performance as compared with many ceiling grids proposed heretofore. If desired, the various frame members may also be ribbed, as at 60, during the same stamping operation so as to provide additional strength in the area where the tongues merge with the main body portions of the various frame members.

As can be seen from the foregoing detailed description, this invention provides an improved interlocking means which can be economically manufactured by relatively simple stamping operations. The interlocking elements are simple to assemble and yet provide a positive locking action which cannot be released by simply drawing the connected members apart. The interlocked members can be disconnected only by depressing the locking tangs while simultaneously retracting the locking tongues from between the receiving tabs. Furthermore, the invention provides all the foregoing advantages in a structure which is of a universal nature, so that only one type of runner section and one type of cross T need be manufactured for any desired grid structure. Also, the interlocking means of this invention inherently provides alignment of the various members being connected and holds the connected members rigidly in such aligned position so that the desired flush fitting is maintained in spite of the usual stresses and strains encountered during normal usage of such structures.

We claim as our invention:

1. In a suspended ceiling system including a plurality of interlocking frame members each of which has a vertical fin and outwardly projecting horizontal flanges at the lower edge of the vertical fin, improved interlocking means for connecting adjacent frame members comprising a locking tongue projecting from the end of one frame member and having a substantially vertical locking surface facing rearwardly of the leading edge of said tongue, a pair of opposed longitudinal, vertically spaced tabs projecting from the vertical fin of the adjacent frame member so as to define a channel for receiving said tongue and holding the tongue firmly against one side of the vertical fin, said tabs being formed from said vertical fin with the opposed longitudinal edges of the tabs being spaced apart so as to form a residual divider web therebetween, one end of said divider web being cut out of said vertical fin so as to form a longitudinal tang having an end portion bent out of the plane of the fin so as to be biased against said tongue as the tongue is inserted between the tabs, the end of said tang being adapted to engage said vertical locking surface on said locking tongue so as to prevent retraction of the tongue from between the tab-s.

2. In a suspended ceiling system including a plurality of interlocking frame members each of which has a vertical fin and outwardly projecting horizontal flanges at the lower edge of the vertical fin, improved interlocking means for connecting adjacent frame members comprising a locking tongue projecting from the end of one frame member and having a substantially vertical locking surface facing rearwardly of the leading edge of said tongue, a pair of opposed longitudinal, vertically spaced tabs projecting from the vertical fin of the adjacent frame member so as to define a channel for receiving said tongue and holding the tongue firmly against one side of the vertical fin, said tabs being formed from said vertical fin with the opposed longitudinal edges of the tabs being spaced apart so as to form a residual divider web therebetween, one end of said residual divider web being cut away from said vertical fin so as to form a longitudinal tang between said tabs with an end portion of said tang being bent out of the plane of said fin so as to be biased against said tongue as the tongue is inserted between the tabs, the end of said tang being adapted to engage the vertical locking surface on said tongue so as to prevent retraction of the tongue from between the tabs, the entrance end of each of said tabs being beveled longitudinally toward the longitudinal edge of the opposed tab so as to form a V-shaped mouth for facilitating the insertion of said tongue and also strengthening the base portion of said tang.

3. In a suspended ceiling system including a plurality of interlocking frame members each of which has a vertical fin and outwardly projecting horizontal flanges at the lower edge of the vertical fin, improved interlocking means for connecting adjacent frame members comprising a locking tongue projecting from the end of one frame member and having a substantially vertical locking surface facing rearwardly of the leading edge of said tongue, a pair of opposed longitudinal, vertically spaced tabs projecting from the vertical fin of the adjacent frame member so as to define a channel for receiving said tongue and holding the 7 tongue firmly against one side of'the vertical fin, said tongue including a relatively wide base portion forming a vertical shoulder for abutting the entrance end of at least one of said longitudinal tabs, and a longitudinal tang formed from the vertical fin between said tabs with an end portion of the tang being bent out of the plane of the vertical fin so as to be biased against said tongue as the tongue is inserted between the tabs, the end of said tang being adapted to engage the vertical locking surface on said locking tongue so as to prevent retraction of the tongue from between the tabs.

4. In a suspended ceiling system including a plurality of interlocking frame members each of which has a vertical fin and outwardly projecting horizontal flanges at the lower edge of the vertical fin, improved interlocking means for connecting adjacent frame members comprising a locking tongue projecting from the end of one frarne member and having a substantially Vertical locking surface facing rearwardly of the leading edge of the tongue, a pair of opposed longitudinal, vertically spaced tabs projecting from the vertical fin so as to define a channel for'receiving said tongue and holding the tongue firmly against one side of the vertical fin, and a longitudinal tang including a base portion integral with the vertical fin adjacent the entrance ends of said tabs and an end portion extending longitudinally between said tabs and biased outwardly from the vertical fin in the same direction as said tabs so as to be biased against said locking tongue as the tongue is inserted between the tabs, the end of said tang being adapted to engage said vertical locking surface on said tongue so as to prevent retraction of the tongue from between the tabs. 7

5. In a suspended ceiling system including a plurality of interlocking frame members each of which has a vertical fin and outwardly projecting horizontal flanges at the lower edge of the vertical fin, improved interlocking means for a connecting adjacent frame members comprising a locking tongue projecting from the end of one frame member and having a substantially vertical locking surface facing rearwardly of the leading edge of said tongue, a pair of opposed longitudinal, vertically spaced tabs projecting from the vertical fin of the adjacent frame member so as to define a channel for receiving said tongue and holding the tongue firmly against one side of the vertical fin, and a longitudinal tang formed from the vertical fin between 7 said tabs with an end portion of said tang being bent out of the plane of the vertical fin so as to be biased against said tongue as the tongue is inserted between the tabs, said tang including a recess in the outwardly biased end portion thereof for facilitating the sliding movement of said tongue over said tang, the end of said tang being adapted to engage said vertical locking surface on the locking tongue so as to prevent retraction of the tongue from between the tabs, said vertical fin including a recess adjacent the outermost end of said tang to enable said tongue to fit flush against said fin and thereby facilitate overlapping engagement of said tang with said locking surface on said tongue.

6. For use in a suspended ceiling system including a plurality of interlocking frame members supported by a plurality of peripheral wall members, an improved wall member comprising a vertical fin and a horizontal flange projecting outwardly from the lower edge of said vertical fin, a longitudinal bead formed on the upper edge of said vertical fin on the opposite side thereof from said horizontal flange so as to bear against the wallto which said member is attached, and a longitudinal groove formed on the same side of said vertical fin as said horizontal flange, said groove being located between the upper and lower edges of said vertical fin to facilitate the bending of said fin due to the deflecting action of said longitudinal bead and thereby urge the lower'portion of said fin firmly against the wall to which it is attached.

7. In a suspended ceiling system including a plurality of interlocking cross members and main runners each of which has a vertical fin and outwardly projecting horizontal flanges at the lower edge of the vertical fin, improved interlocking means for connecting the cross members to the main runners comprising a locking tongue projecting longitudinally from the end of each cross member and having a substantially 'vertical locking surface facing rearwardly of the leading edge of said tongue, each cross member including an end portion adapted to fit over one of the horizontal flanges of the main runner into abutting engagement With the vertical fin of the main runner with said tongue being bent at a right angle to the vertical fin of the cross member so as to fit along one side of the vertical fin of the main runner; a pair of opposed longitudinal, vertically spaced tabs projecting from the vertical fin of the frame member so as to define a channel for receiving said tongue and holding the same firmly against one side of the vertical fin of the main runner; and a longitudinal tang formed from the vertical fin of the main 7 runner between said tabs with an end portion of said tangv being bent out of the plane of the vertical fins so as to be biased against the end portion of said tongue as it is inserted between the tabs, the end of said tang being adapted to'engage said vertical locking surface on the tongue so as to prevent retraction of the tongue from between the tabs, said tongue including a base portion having 7 atleast one vertical shoulder for engaging the entrance end of at least one of said tabs.

References Cited UNITED STATES PATENTS 2,663,390 12/1953 Dordel 52-482 X 2,990,921 7/1961 Wilde 287189.36 3,084,401 4/ 1963 Findlay a 52484 X 3,169,614 2/ 1965 McCoy 52-484 3,221,466 12/ 1965 Downing et al 52-729 X FOREIGN PATENTS 1,333,580 6/1963 France.

KENNETH DOWNEY, Prim-dry Examiner.

Images