SUSPENDED CEILING BEAM WITH A REINFORCED BULB

Abstract

A beam with a reinforced bulb for a suspended ceiling formed from a single sheet of rolled steel. This beam has a web with flanges attached to the bottom and a bulb attached at the top. The bulb includes a pleat that may increase the load-bearing capabilities of the beam.

Claims

1. A beam for a suspended ceiling comprising: a web having a first edge opposite a second edge; a bulb, including a pleat, at the first edge of the web; 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 beam is formed from a single sheet of material.

3. The beam of claim 2, wherein the beam is formed from a material selected from a group consisting of metals, polymers, or carbon fiber.

4. The beam of claim 2, wherein the material has a thickness of between about 0.008 inches and about 0.05 inches.

5. The beam of claim 1, wherein the bulb contains two or more pleats.

6. 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.

7. The beam of claim 6, 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.

8. The beam of claim 1, further comprising a faceplate connecting the first flange and the second flange.

9. A suspended ceiling comprising: a grid of beams below a structural framework, the beams comprising: a web having a first edge opposite a second edge, a bulb, including a pleat, at the first edge of the web, and two flanges opposite one another at the second edge of the web extending substantially perpendicularly out from the web; a plurality of upper threaded hang rods above the grid of beams secured into the structural support, each of the upper threaded rods secured to the grid of beams by a hang clip; a plurality of lower threaded load rods below the grid of beams, each of the lower threaded load rods secured to the grid of beams by a load clip; and wherein the lower threaded load rods and the upper threaded hang rods enable tensile forces applied to the grid of beams by the load to pass through the grid of beams to the structural support without creating torsion or twisting forces in the grid of beams.

10. The suspended ceiling of claim 9 further comprising: a load below the grid of beams supported by the lower threaded load rods.

11. The suspended ceiling of claim 9, wherein the suspended ceiling remains balanced, level, and intact even though the load below the grid of beams is not spread evenly over the grid of beams.

12. The suspended ceiling of claim 9, wherein the hang clips and the load clips transmit the tensile forces to and from the grid beams without bending or twisting.

13. The suspended ceiling of claim 9, wherein the load clips and the hang clips grip the beams without weakening the beams.

14. The suspended ceiling of claim 9, wherein the beam is formed from a single sheet of material.

15. The suspended ceiling of claim 14, wherein the beam is formed from a material selected from a group consisting of metals, polymers, or carbon fiber.

16. The suspended ceiling of claim 14, wherein the material has a thickness of between about 0.008 inches and about 0.05 inches.

17. The suspended ceiling of claim 9, wherein the bulb contains two or more pleats.

18. The suspended ceiling of claim 9, 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.

19. The suspended ceiling of claim 18, 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.

20. The suspended ceiling of claim 9, wherein the beam includes a faceplate connecting the first flange and the second flange.

Description

BRIEF SUMMARY OF THE SEVERAL VIEWS OF THE DRAWING

[0012] The invention is best understood from the following detailed description when read in connection with the accompanying drawing and appended claims. It is emphasized that, according to common practice, the various features of the drawing are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawing are the following figures:

[0013] FIG. 1 is a perspective view of one embodiment of the beam;

[0014] FIG. 2 is a perspective view of the opposite side of the beam of FIG. 1;

[0015] FIG. 3 is a front view of one embodiment of the beam;

[0016] FIG. 4 is an enlarged view of one embodiment of the pleat of the beam;

[0017] FIG. 5 is an enlarged view of one embodiment of the flanges with a face cap;

[0018] FIG. 6A is one embodiment of a partially constructed beam with two pleats formed but not compressed;

[0019] FIG. 6B is one embodiment of a partially constructed beam with two pleats compressed and a zigzag added to each end;

[0020] FIG. 6C is one embodiment of a partially constructed beam with two pleats and two flanges formed and the flat stock being folded in half to form the beam;

[0021] FIG. 6D is one embodiment of a fully formed beam; and

[0022] FIG. 7 is one embodiment of a method used to create one embodiment of a fully formed beam.

DETAILED DESCRIPTION

[0023] 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 combination of features that may exist alone or in other combinations of features.

[0024] 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.

[0025] Beam Structure

[0026] FIG. 1 depicts an exemplary embodiment of the beam 100 according to the present disclosure. The beam 100 includes at least one bulb 130 which includes at least one pleat 132. 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 form the web 110 are connected to the bottom edge 112.

[0027] Bulb

[0028] In simple loading conditions, the bulb 130 of the beam 100 is the weakest link. When the face of the beam 100 (i.e., the bottom edge 112 with the flanges 120) is under tension it typically will not fail under load tests. When the bulb 130, however, is under compression it may buckle (i.e., fail), which causes grid collapse. Increasing the beam height to gain loading capacity is not desirable due to installation constraints. Increasing the gauge of the material, wastes the material in areas that do not need increased performance (i.e., the bottom edge 112 and web 110). The pleat 132 at the top of the beam 100 is the most efficient way to increase the load capacity of the beam 100 while not wasting material. Here, the bulb 130 may also have multiple pleats 132. For example, in FIG. 1 the bulb 130 contains two pleats 132. The bulb 130 disclosed may contain more than two pleats 132. Indeed, the bulb 130 may have three, four or five pleats 132.

[0029] Web

[0030] In FIGS. 1 and 2 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 312 is stitched to the second surface 314 by forcing a portion of the first surface 312 through a portion of the second surface 314 creating a protuberance 310 in the second surface 314. 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.

[0031] Flanges

[0032] To provide additional structural support, and as illustrated in FIG. 5 a cap 410 may be added to the bottom of the flanges 120 and be wrapped around to the top of the flanges 120. Preferably the cap 410 is a separate piece of material. The cap 410 may also be an extension of one or both of the flanges 120.

[0033] Beam Manufacture

[0034] FIGS. 6A-4D depict the manufacture of an exemplary embodiment of the beam 100. Here, the beam 100 is manufactured using a roll-forming process. The process begins with a flat metal stock 200 that is fed into a series of rolls. The pleats 132 at the top of the bulb 130 may be formed first, being drawn into the center of the stock 200 and folded over. The pleats 132 may then be flattened and the bottom of the bulb 130 may be formed via a zigzag to provide a radius corner. In the subsequent roll passes, the outer edges of the stock 200 may be formed to provide the web 110 and flanges 120. The outer edges of the stock 200 may then be drawn to the center to fold the entire stock 200 in half vertically. Additional forming provides the peak of the bulb 130. The first surface 312 is then punched through the second surface 314 forming an indentation 316 in the first surface 312 and a protuberance 310 in the second surface 314 (i.e., a stitch). This stitch locks the metal together. A painted strip used to form the flange cap 410 may then be introduced to the face of the beam 100 (i.e., bottom of the flanges 114). The edges of the flange cap 410 may then be folded over the edges of the flanges 120 to form a hem and lock the flange cap 410 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 is completed in a press to add end details, routs, and wire holes. This process results in a complete, saleable product.

[0035] Beam Materials

[0036] It will be understood that the beam 100 may be constructed out of any bendable material such as metals, polymers, or carbon fiber. Preferably, the beam 100 is manufactured from metal. More preferably, the beam 100 is manufactured from rolled steel.

[0037] Beam Dimensions

[0038] The height of the beam 100 is between approximately 1 inch (2.54 cm) to 6 inches (15.24 cm). More preferably, the height of the beam 100 is between approximately 1.50 inches (3.81 cm) to 1.75 inches (4.45 cm). Most preferably, the height of the beam 100 is between approximately 1.65 inches (4.19 cm) and 1.70 inches (4.32 cm).

[0039] The flange width of the beam 100 is between approximately 0.5 inches (1.27 cm) and 4.00 inches (10.16 cm). More preferably, the flange width of the beam is between approximately 0.56 (1.42 cm) and 0.94 inches (2.39 cm). It will be further understood that the inclusion a cap 410 may further increase the width of the flanges 120 of the beam 100.

[0040] 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). More preferably, the material gauge may be between approximately 0.01 (0.025 cm) and 0.018 inches (0.046 cm).

[0041] Incorporation into a Ceiling System

[0042] The disclosed beam 100 may be incorporated into a ceiling system grid framework to increase the load capacity of the ceiling system. This first requires the formation of 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.).

[0043] 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.

[0044] The grid can be adapted to transmit relatively heavy loads from below the suspended ceiling to structural supports above the suspended ceiling. A skilled artisan would further understand that heavy loads are those loads such as data banks attached to the suspended ceiling, whereas light loads may be considered most light fixtures attached to the suspended ceiling.

[0045] To increase the load capacity of the suspended ceiling, and therefore the ability of the suspended ceiling to support heavy loads, threaded load and hang rods may be secured to the suspended ceiling grid by clips shaped to transmit loads vertically through the webs of the beam 100, without twisting or bending the beam 100 in the grid. Examples of such clips are disclosed in U.S. Pat. No. 9,255,402, incorporated in this document by reference.

[0046] 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, notwithstanding the heavy loads that are being supported through the suspended ceiling by the clips and the threaded rods secured to the clips. 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.

[0047] In this configuration, relatively heavy loads may be suspended from the grid without the need to incorporate heavy forged metal beams into the grid. The heavy loads may be secured to the beam 100 by lower threaded load rods secured to the beam 100 with grid beam load clips, preferably attached to the face of the beam 100. These clips may be secured in a manner that passes the loads in a vertical or approximately vertical manner upward through the web 110 of the beam 100 to the hang clips and then from there up through to the structural support. In one embodiment, the load clips and/or the hang clips grip the beams 100 without weakening the beams 100.

[0048] In this way, the load hung below the suspended ceiling passes upwardly through the web of the beam, without twisting or bending the beam. The grid beam clips above the ceiling are preferably spaced on the web 110 to balance the load from the grid beam load clips below the ceiling, and may be further designed to avoid twisting or bending of the beam 100.

[0049] Structural Load Tests

[0050] The pleat 132 at the top of the disclosed beam 100 is the most efficient way to increase load capacity of the beam 100. Indeed, the inclusion of the pleat 132 increases load capacity by over twenty percent (20%) while only increasing material usage by approximately 11-12%.

[0051] Two vertical load failure tests were conducted on a rolled steel beam with the design similar to the beam design disclosed in U.S. Pat. No. 6,138,416 (i.e., a beam with a bulb that does not contain a pleat). Specifically, the tests were conducted on a non-pleated bulb with a length of forty-eight inches, with a single stitch in the web, a height of 1.670 inches, a flange width of 0.558 inches and a material gauges of 0.01 inches (0.026 cm), and 0.015 inches (0.038 cm). During the tests, weight was applied to the center. The results of the failure tests are disclosed below in Table 1:

TABLE-US-00001 TABLE 1 Load at Load at Metal Gauge L/360 Failure Inches Cm Lbs Kg Lbs Kg 0.010 0.026 40.5 18.36 93 42.1841 0.015 0.038 50.6 22.97 144 65.3172

[0052] Eight vertical load failure tests were conducted on a rolled steel beam 100 with a structure as disclosed in FIG. 1. Specifically, the eight tests were conducted on a forty-eight inch beam 100, with two pleats 132, a single stitch in the web 110, and the following beam dimensions in inches (cm):

TABLE-US-00002 TABLE 2 Beam Height Flange Width Metal Gauge Identifier Inches Cm Inches Cm Inches Cm A 1.683 4.275 0.564 1.433 0.010 0.026 B 1.678 4.262 0.560 1.422 0.013 0.033 C 1.671 4.244 0.561 1.425 0.015 0.038

[0053] The results of the three vertical load failure tests on Beam A are outlined in Table 2 below where deflection is measured in inches (cm):

TABLE-US-00003 TABLE 3 Run 1 Deflection Run 2 Deflection Run 3 Deflection Lbs. Kgs. Inches Cm Inches Cm Inches Cm 8 3.629 0.020 0.051 0.020 0.051 0.020 0.051 12 5.443 0.030 0.076 0.030 0.076 0.030 0.076 16 7.257 0.041 0.104 0.040 0.102 0.040 0.102 20 9.072 0.051 0.130 0.051 0.130 0.051 0.130 24 10.886 0.061 0.155 0.061 0.155 0.061 0.155 28 12.701 0.072 0.183 0.072 0.183 0.072 0.183 32 14.515 0.083 0.211 0.083 0.211 0.083 0.211 36 16.329 0.094 0.239 0.095 0.241 0.094 0.239 40 18.144 0.105 0.267 0.108 0.274 0.106 0.269 44 19.958 0.116 0.295 0.121 0.307 0.119 0.302 48 21.772 0.128 0.325 0.133 0.338 0.132 0.335 52 23.587 0.142 0.361 0.157 0.399 0.145 0.368 56 25.401 0.153 0.389 0.171 0.434 0.170 0.432 60 27.216 0.166 0.422 0.185 0.470 0.182 0.462 64 29.030 0.188 0.478 0.198 0.503 0.196 0.498 68 30.844 0.202 0.513 0.212 0.538 0.209 0.531 72 32.659 0.216 0.549 0.226 0.574 0.224 0.569 76 34.473 0.230 0.584 0.241 0.612 0.237 0.602 80 36.287 0.245 0.622 0.256 0.650 0.250 0.635 84 38.102 0.263 0.668 0.270 0.686 0.265 0.673 88 39.916 0.276 0.701 0.284 0.721 0.279 0.709 92 41.730 0.293 0.744 0.301 0.765 0.296 0.752 96 43.545 0.308 0.782 0.318 0.808 0.313 0.795 100 45.359 0.332 0.843 0.348 0.884 0.335 0.851 104 47.174 Failure Failure Failure

[0054] The result of the two failure tests on Beam B are outlined in Table 4 below where deflection is measured in inches (cm):

TABLE-US-00004 TABLE 4 Run 1 Deflection Run 2 Deflection Lbs. Kgs. Inches Cm Inches Cm 8 3.629 0.016 0.041 0.018 0.046 12 5.443 0.025 0.064 0.026 0.066 16 7.257 0.033 0.084 0.035 0.089 20 9.072 0.042 0.107 0.044 0.112 24 10.886 0.051 0.130 0.053 0.135 28 12.701 0.06 0.152 0.061 0.155 32 14.515 0.069 0.175 0.07 0.178 36 16.329 0.078 0.198 0.079 0.201 40 18.144 0.088 0.224 0.088 0.224 44 19.958 0.097 0.246 0.098 0.249 48 21.772 0.108 0.274 0.108 0.274 52 23.587 0.118 0.300 0.117 0.297 56 25.401 0.128 0.325 0.128 0.325 60 27.216 0.138 0.351 0.139 0.353 64 29.030 0.16 0.406 0.161 0.409 68 30.844 0.17 0.432 0.172 0.437 72 32.659 0.182 0.462 0.186 0.472 76 34.473 0.192 0.488 0.197 0.500 80 36.287 0.202 0.513 0.208 0.528 84 38.102 0.213 0.541 0.219 0.556 88 39.916 0.224 0.569 0.231 0.587 92 41.730 0.236 0.599 0.242 0.615 96 43.545 0.246 0.625 0.254 0.645 100 45.359 0.257 0.653 0.265 0.673 104 47.174 0.269 0.683 0.277 0.704 108 48.988 0.281 0.714 0.288 0.732 112 50.802 0.291 0.739 0.302 0.767 116 52.617 0.304 0.772 0.313 0.795 120 54.431 0.32 0.813 0.326 0.828 124 56.245 0.333 0.846 0.339 0.861 128 58.060 0.346 0.879 0.354 0.899 132 59.874 0.365 0.927 0.381 0.968 136 61.689 Failure Failure

[0055] The results of the three failure tests on Beam C are outlined in Table 5 below where deflection is measured in inches (cm):

TABLE-US-00005 TABLE 5 Run 1 Run 2 Run 3 Deflection Deflection Deflection Lbs. Kgs. Inches Cm Inches Cm Inches Cm 8 3.629 0.016 0.041 0.016 0.041 0.017 0.043 12 5.443 0.024 0.061 0.024 0.061 0.025 0.064 16 7.257 0.033 0.084 0.033 0.084 0.034 0.086 20 9.072 0.041 0.104 0.041 0.104 0.041 0.104 24 10.886 0.049 0.124 0.049 0.124 0.05 0.127 28 12.701 0.058 0.147 0.057 0.145 0.058 0.147 32 14.515 0.066 0.168 0.065 0.165 0.066 0.168 36 16.329 0.074 0.188 0.073 0.185 0.075 0.191 40 18.144 0.082 0.208 0.082 0.208 0.083 0.211 44 19.958 0.09 0.229 0.09 0.229 0.091 0.231 48 21.772 0.099 0.251 0.099 0.251 0.099 0.251 52 23.587 0.108 0.274 0.106 0.269 0.107 0.272 56 25.401 0.116 0.295 0.115 0.292 0.116 0.295 60 27.216 0.124 0.315 0.124 0.315 0.124 0.315 64 29.030 0.133 0.338 0.132 0.335 0.132 0.335 68 30.844 0.145 0.368 0.14 0.356 0.14 0.356 72 32.659 0.155 0.394 0.158 0.401 0.158 0.401 76 34.473 0.163 0.414 0.167 0.424 0.167 0.424 80 36.287 0.172 0.437 0.176 0.447 0.177 0.450 84 38.102 0.182 0.462 0.185 0.470 0.185 0.470 88 39.916 0.192 0.488 0.194 0.493 0.194 0.493 92 41.730 0.201 0.511 0.203 0.516 0.203 0.516 96 43.545 0.21 0.533 0.211 0.536 0.212 0.538 100 45.359 0.219 0.556 0.221 0.561 0.221 0.561 104 47.174 0.228 0.579 0.23 0.584 0.23 0.584 108 48.988 0.237 0.602 0.239 0.607 0.239 0.607 112 50.802 0.246 0.625 0.249 0.632 0.248 0.630 116 52.617 0.256 0.650 0.258 0.655 0.257 0.653 120 54.431 0.265 0.673 0.268 0.681 0.267 0.678 124 56.245 0.275 0.699 0.277 0.704 0.276 0.701 128 58.060 0.285 0.724 0.287 0.729 0.286 0.726 132 59.874 0.294 0.747 0.297 0.754 0.296 0.752 136 61.689 0.305 0.775 0.308 0.782 0.306 0.777 140 63.503 0.314 0.798 0.318 0.808 0.315 0.800 144 65.317 0.325 0.826 0.328 0.833 0.326 0.828 148 67.132 0.337 0.856 0.339 0.861 0.337 0.856 152 68.946 0.346 0.879 0.351 0.892 0.346 0.879 156 70.760 0.357 0.907 0.363 0.922 0.356 0.904 160 72.575 0.369 0.937 0.376 0.955 0.368 0.935 164 74.389 0.379 0.963 0.391 0.993 0.379 0.963 168 76.203 0.391 0.993 0.414 1.052 0.392 0.996 172 78.018 Failure Failure 0.406 1.031 176 79.832 0.443 1.125 180 81.647 Failure

[0056] As can be seen, the inclusion of the pleat 132 increased the load capacity of the beam 100 while at the same time minimizing the requirements for the incorporation of additional material (i.e., minimizing costs).

[0057] 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.