LOW PROFILE SUSPENDED CEILING BEAM

Abstract

A low profile beam. This beam has a web with flanges attached to the bottom and a bulb attached to the top. The bulb is an inverted triangle connected to one edge of the web, with flanges projecting from the opposite edge of the web. The top face of the bulb is scored. In addition, the angled faces of the bulb and the flanges may be scored. The beam may be further incorporated into a ceiling system.

Claims

1. A beam for a suspended ceiling, comprising: a web having a first edge opposite a second edge; a bulb having: a top face having a scoring line substantially parallel to the web and located along the length of the top face, and two angled faces of substantially equal width, each in contact with the first edge of the web and the top face, wherein the top face and angled faces form an inverted triangle; and two flanges opposite one another at the second edge of the web extending substantially perpendicularly out from the web.

2. The beam of claim 1, wherein the top face and angled faces define an equilateral triangle.

3. The beam of claim 1, wherein the angled faces include scoring lines substantially parallel to the web and located along the length of the angled faces.

4. The beam of claim 1, wherein the flanges include scoring lines substantially parallel to the web and located along the length of the flanges.

5. The beam of claim 1, wherein the height of the beam is less than the combined widths of the two flanges.

6. The beam of claim 1, wherein the width of one of the angled faces of the bulb is greater than the width of the top face of the bulb.

7. The beam of claim 1, wherein the width of the top face of the bulb is between about half the combined width of the flanges and about one sixth the combined width of the flanges.

8. The beam of claim 1, wherein the beam is formed from a single sheet of material.

9. The beam of claim 8, wherein the beam is formed from one or a combination of metals, polymers, and carbon fiber.

10. The beam of claim 8, wherein the material has a thickness of between about 0.008 inches and about 0.05 inches.

11. The beam of claim 1, wherein the web is comprised of a first surface substantially parallel to a second surface wherein the first surface and the second surface are joined together by a stitch.

12. The beam of claim 11, wherein the stitch comprises a portion of the first surface which passes through a portion of the second surface creating an indentation in the first surface and a protuberance in the second surface.

13. A suspended ceiling configured for location proximate a plenum space, the ceiling comprising: a grid formed of main beams running substantially parallel to one another connected by cross beams, wherein the cross beams include: a web having a first edge opposite a second edge; a bulb having; a top face having scoring line substantially parallel to the web and located along the length of the top face, and two angled faces of substantially equal width, each in contact with the first edge of the web and the top face, wherein the top face and angled faces form an inverted triangle; and two flanges opposite one another at the second edge of the web extending substantially perpendicularly out from the web, wherein the grid is adapted to maximize the plenum space.

14. The suspended ceiling of claim 13, wherein the suspended ceiling remains balanced, level, and intact even though a load below the grid of beams is not spread evenly over the grid of beams.

15. The suspended ceiling of claim 14, wherein the web is comprised of a first surface substantially parallel to a second surface wherein the first surface and the second surface are joined together by a stitch.

16. The suspended ceiling of claim 15, wherein the stitch comprises a portion of the first surface which passes through a portion of the second surface creating an indentation in the first surface and a protuberance in the second surface.

Description

DETAILED DESCRIPTION

[0034] The features and benefits of the disclosed beam are illustrated and described by reference to exemplary embodiments. The disclosure also includes the drawing, in which like reference numbers refer to like elements throughout the various figures that comprise the drawing. This description of exemplary embodiments is intended to be read in connection with the accompanying drawing, which is to be considered part of the entire written description. Accordingly, the disclosure expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combinations of features that may exist alone or in other combinations of features.

[0035] In the description of embodiments, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as lower, upper, horizontal, vertical, above, below, up, down, top, and bottom as well as derivatives thereof (e.g., horizontally, downwardly, upwardly, etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be construed or operated in a particular orientation. Terms such as attached, affixed, connected, coupled, interconnected, and similar terms refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both moveable or rigid attachments or relationships, unless expressly described otherwise.

[0036] Beam Structure

[0037] FIG. 1 depicts an exemplary embodiment of the beam 100 according to the present disclosure. The beam 100 includes at least one bulb 130. The bulb 130 is connected to a vertical web 110, which has two edges (i.e., a top edge 114 and a bottom edge 112). Two flanges 120 which extend opposite each other and substantially perpendicularly out from the bottom edge 112 of the web 110, are connected to the bottom edge 112. The two sides of the web 110 are then connected by a stitch 140.

[0038] Bulb

[0039] In typical suspended ceiling beams the bulb is square or rectangular shaped. Such bulbs are only 0.25 inches (0.64 cm) wide. This width is derived from acoustical ceilings where the bulb width is limited to allow for the ceiling panels to be installed. Such reduced width extends to additional ceiling elements such as lighting fixtures and air diffusers, which are themselves sized to fit bulbs having a width of 0.25 inches (0.64 cm). The size of conventional bulbs was also adapted to drywall grid. Regardless, standard bulbs having a width of 0.25 inches (0.64 cm) do not produce a shape with adequate area moment of inertia to meet the load/deflection requirements for one layer of inch (1.6 cm) drywall.

[0040] To reduce the profile or height of the beam 100 while still maintaining the rigidity to hold inch (1.6 cm) drywall, the present beam utilizes a bulb 130 that has an inverted triangle shape. In such a configuration, the bulb 130 includes a top face 132 connected to two angled faces 134 each connected to the web 110. The profile of the angled faces 134 will be substantially similar, such that the top face 132 and the two angled faces 134 form an inverted isosceles triangle. In another embodiment, the width of the top face 132 will be the same as both of the angled faces 134 thereby forming an inverted equilateral triangle.

[0041] In one embodiment, the width of the top face 132 may be between 0.33 inches and 2.0 inches (0.85 cm and 5.08 cm). In another embodiment, the width of the top face 132 may be between 0.5 inches and 1.5 inches (1.27 cm and 3.81 cm). In a further embodiment, the width of the top face 132 may be between 0.6 inches and 1.0 inches (1.52 cm and 2.54 cm). Such dimensions may produce a shape with adequate area moment of inertia to meet the load/deflection requirements for one layer of inch (1.6 cm) drywall and provide an increased surface area to attach the beam 100 to the structural ceiling.

[0042] In one embodiment, the width of each angled face 134 may be between 0.33 inches and 2.5 inches (0.85 cm and 6.35 cm). In another embodiment, the width of each angled face 134 may be between 0.5 inches and 2.0 inches (1.27 cm and 5.08 cm). In a further embodiment, the width of each angled face 134 may be between 0.6 inches and 1.5 inches (1.52 cm and 3.81 cm). Such dimensions may produce a shape with adequate area moment of inertia to meet the load/deflection requirements for one layer of inch (1.6 cm) drywall and provide an increased surface area to attach the beam 100 to the structural ceiling. In another embodiment, the width of each angled face 134 may be greater than the width of the top face 132.

[0043] To assist in securing the beam 100 to the structural ceiling, in one embodiment the top face 132 has a score line 136. The score line 136 may assist in aligning fasteners 600 (e.g., screws) or prevent such fasteners 600 from wobbling or walking when they are driven into the beam 100 to secure the beam 100 to other beams or the structural ceiling. The score line 136 may be located along a centerline of the length of the top face 132. In other embodiments, the top face 132 may contain two or more scoring lines 136, each located a substantially equal distance from the centerline of the length of the top face 132.

[0044] In one embodiment, the scoring lines 136 comprise protuberances projecting towards the flanges 120. In another embodiment, the scoring lines 136 comprise protuberances projecting away from the flanges 120. In a further embodiment, the scoring line comprise apertures through the surface of the top face 132. Such apertures may define a circle, square, or diamond shape.

[0045] In another embodiment one or both of the angled faces 134 have a score line 136. Such score line 136 may be located along a centerline of the length of the angled face 134. In other embodiments, the angled face 134 may contain two or more scoring lines 136, each located a substantially equal distance from the centerline of the length of the angled face 134.

[0046] In one embodiment, the scoring lines 136 comprise protuberances projecting towards the top face 132. In another embodiment, the scoring lines 136 comprise protuberances projecting away from the top face 132. In a further embodiment, the scoring lines 136 comprise apertures through the surface of the angled face 134. Such apertures may define a circle, square, or diamond shape.

[0047] Web

[0048] In FIG. 5 a dual web 110 comprised of two vertical sheets stitched together is disclosed. The vertical sheets comprise two surfaces opposite one another. The first surface 512 is stitched to the second surface 514 by forcing a portion of the first surface 512 through a portion of the second surface 514 creating a protuberance 510 in the second surface 514. It is further understood that the web 110 may be comprised of a single sheet or multiple sheets (e.g., two, three, or four sheets) of material.

[0049] In one embodiment the height of the web 110 is greater than 0.25 inches (0.64 cm).

[0050] In another embodiment the sum of the height of the web 110 and the height of the bulb 130 is less than the combined width of the flanges 120, and the width of the top face 132 is greater than 0.25 inches (0.64 cm) and equal to or less than the width of one flange 120. Such dimensions may assist in packing, storing, or stacking the beams 100.

[0051] Flanges

[0052] In one embodiment, the edges of the flanges 120 are folded back over each other. In one embodiment, the edge of the flange 120 is folded back over itself in the direction of the web 110. In another embodiment, the edge of the flange 120 is folded back over itself in the direction opposite the web 110.

[0053] To assist in securing the beam 100 to a ceiling system, in one embodiment the flanges 120 have score lines 136. Such score lines 136 may assist in aligning fasteners 600 (e.g., screws) or prevent such fasteners 600 from wobbling or walking when they are driven into the beam 100 to secure the beam 100 to other beams or the ceiling system. Such score lines 136 may be located along a centerline of the length of the flanges 120. In other embodiments, the flanges 120 may contain two or more scoring lines 136, each located a substantially equal distance from the centerline of the length of the flange 120.

[0054] In another embodiment, a cap 150 is added to the bottom of the flanges 120 and wrapped around to the top of the flanges 120. Preferably the cap 150 is a separate piece of material. The cap 150 may also be an extension of one or both of the flanges 120.

[0055] Beam Manufacture

[0056] FIG. 9 depicts the manufacture of an exemplary embodiment of the beam 100. The beam 100 is manufactured using a roll-forming process. The process begins with a flat material (e.g., metal, polymer, or carbon fiber) stock 900 that is fed into a series of rolls. The dimensions of the top face 132 and angled faces 134 may be formed first. In the subsequent roll passes, the outer edges of the stock 900 may be formed to provide the web 110 and flanges 120. The outer edges of the stock 900 may then be folded down at the intersection of the top face 132 and the angled faces 134 to fold the stock 900 vertically. Additional forming provides the score lines 136 of the bulb 130. The first surface 512 is then punched through the second surface 514 forming indentations 516 in the first surface 512 and the protuberances 510 in the second surface 514 (i.e., a stitch). This stitch locks the material together. A painted or unpainted strip used to form the flange cap 150 may then be introduced to the face of the beam 100 (i.e., the bottom of the flanges 120). The edges of the cap 150 are then be folded over the edges of the flanges 120 to form a hem and lock the flange cap 150 onto the beam 100. The beam 100 is then straightened to equalize the stresses introduced in the forming process and cut off to length. Secondary processing may be completed in a press to add end details, routs, and wire holes. With or without this secondary process, the result is a complete, saleable product.

[0057] Beam Materials

[0058] It will be understood that the beam 100 may be constructed out of any bendable material such as metals, polymers, or carbon fiber. In one embodiment, the beam 100 is manufactured from metal. For example, the beam 100 may be is manufactured from rolled steel.

[0059] Beam Dimensions

[0060] FIG. 6 depicts different embodiments of the profile ratios of the beam 100. In one embodiment, the height of the beam 100 (identified as distance B) is less than the combined widths of the two flanges 120 (identified as distance A). Such a profile may provide obstruction clearance in reduced plenum space applications while still providing increased area for fastener attachment. In another embodiment, the width of the top face 132 (identified as distance D) is between about half the combined width of the flanges 120 and about one sixth the combined width of the flanges 120. Such dimensions may provide greater stability in product packout for shipping. In another embodiment, the width of the angled faces 134 (identified as distance C) is greater than the width of the top face 132 (identified as distance D). Such dimensions may provide greater stability for installation of the beam or stability with regard to weight distribution.

[0061] Each flange 120 of the beam 100 may have a width of between approximately 0.5 inches (1.27 cm) and 2.00 inches (5.08 cm). In one embodiment, the individual flange width of the beam 100 is between approximately 1.0 inches (2.54 cm) and 1.75 inches (4.45 cm). In another embodiment, each individual flange width is about 1.5 inches (3.81 cm). In such an embodiment, the combined flange width (identified as distance A) may be 3.0 inches (7.62 cm). It will be further understood that the inclusion of the cap 150 may further increase the width of the flanges 120 of the beam 100.

[0062] The material gauge from which the beam 100 may be constructed may be between approximately 0.008 inches (0.020 cm) and 0.05 inches (0.127 cm). In one embodiment, the material gauge is between approximately 0.01 inches (0.025 cm) and 0.018 inches (0.046 cm).

[0063] Incorporation into a Ceiling System

[0064] The disclosed beam 100 may be incorporated into a low profile ceiling system grid framework. In another embodiment, shown in FIGS. 10A and 10B the beam 100 is attached to a molding 800 using a fastener 600. In yet another embodiment, shown in FIGS. 11A and 11B the beam 100 is attached to a main beam 830. Such a system may permit the beam 100 to run underneath obstructions 1000 within the plenum while still minimizing the plenum space.

[0065] In one embodiment, the molding 800 or main beam 830 includes a pocket 810 and a protuberance 820. FIGS. 8A and 8B depict one such embodiment. The protuberance 820 may project outward from the molding 800 or main beam 830 in a direction substantially parallel to the length of the molding 800 or main beam 830. In one embodiment, the protuberance 820 may include a pointed or serrated edge. The pocket 810 and the protuberance 820 may also be punched out of the molding 800 or main beam 830. In such an embodiment, the beam 100 may be slid into the pocket 810 and then back against the protuberance 820 in a direction substantially opposite the direction of the projection of the protuberance 820 thereby locking the beam 100 in place.

[0066] In creating the ceiling system, an installer first forms a grid framework with tessellation (i.e., a pattern of flat shapes with no overlaps or gaps). The tessellations may be a regular tessellation (i.e., repeating regular polygons such as triangles, squares, rectangles, hexagons, etc.) or semi-regular tessellations (i.e., a grid made of two or more regular polygons such as hexagons/triangles, triangles/squares, hexagons/squares/triangles, octagons/squares, etc.).

[0067] The grid is suspended from a structural support, such as a structural ceiling, by hang wires or hang rods located above the grid of beams 100. Panels may also be placed in the grid openings or drywall attached to the grid face.

[0068] In other embodiments, as shown in FIG. 7C, the grid or beams 100 may be attached to a structural ceiling 870 with brackets 850. Such brackets 850 may be angled. The brackets 850 may also be attached to the beam 100 using fasteners 600 driven through the top face 132 and/or one or both of the angled faces 134. A tool (e.g., a drill) 860 may be used to drive the fasteners 600.

[0069] The load and hang clips may be further spaced on the suspended ceiling at locations that maintain the level and balance of the suspended ceiling. In one embodiment, the suspended ceiling may remain balanced, level, and intact even though the load below the grid of beams 100 is not spread evenly over the grid of beams 100.

[0070] As can be seen, the inclusion of the scoring lines 136 allows for the precise fastening of the beam 100 to the suspended ceiling or to other beams while at the same time minimizing the requirements for the incorporation of additional material (i.e., minimizing costs).

[0071] Although illustrated and described above with reference to certain specific embodiments and examples, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. It is expressly intended, for example, that all ranges broadly recited in this document include within their scope all narrower ranges which fall within the broader ranges. It is also expressly intended that the steps of the methods of using the various devices disclosed above are not restricted to any particular order.