US20240084592A1

US20240084592A1 - Cross rail and suspended ceiling system formed therefrom

Info

Publication number: US20240084592A1
Application number: US17/941,834
Authority: US
Inventors: Alex Keurban
Original assignee: K8 Vic Pty Ltd
Priority date: 2022-09-09
Filing date: 2022-09-09
Publication date: 2024-03-14

Abstract

A cross rail to which one or more battens of a suspended ceiling system can be secured, the cross rail comprising an elongate channel having an upper wall via which one or more ceiling suspension clips are engageable to support the cross rail; opposed lateral walls extending downwardly from the upper wall; and pairs of opposed latching members via which one or more battens are securable to the cross rail, each latching member of a pair extending downwardly from a respective lateral wall such that, in use, a batten is securable substantially perpendicularly to the cross rail between two adjacent pairs of opposed latching members.

Description

FIELD OF THE INVENTION

The present patent specification discloses a cross rail for use in a suspended ceiling system.

BACKGROUND

In assembling suspended ceiling systems, cross rails (also referred to as top cross rails) are used to interconnect ceiling suspension clips and battens. In particular, the cross rail is supported from one or more ceiling suspension clips, and in turn, one or more battens are secured to and supported by one or more cross rails.
Certain prior art cross rails are configured such that battens are securable thereto via an intermediate member. In one example, an additional clipping member must first be secured across an upper end of the elongate batten, and then the clipping member is itself inserted into the channel of the cross rail. This arrangement involves additional components and thus complexity and labour; provides an interconnection between the cross rail and batten that may not be able to withstand higher ceiling loads, particularly if seismic activity is to be considered; and positional adjustments of the batten relative to the cross rail can be cumbersome, particularly after the clipping member is already secured to the batten and inserted into the cross rail.
There is a need to address the above, and/or at least provide a useful alternative.

SUMMARY

According to a first aspect of the present invention, there is provided a cross rail to which one or more battens of a suspended ceiling system can be secured, the cross rail comprising:

- an elongate channel having an upper wall via which one or more ceiling suspension clips are engageable to support the cross rail;
- opposed lateral walls extending downwardly from the upper wall; and
- pairs of opposed latching members via which one or more battens are securable to the cross rail, each latching member of a pair extending downwardly from a respective lateral wall such that, in use, a batten is securable substantially perpendicularly to the cross rail between two adjacent pairs of opposed latching members.

In embodiments of the cross rail, the latching members project downwardly from the lateral walls. For example, adjacent latching members may be spaced apart from one another along a length of the lateral walls, which spacing is shaped and sized to receive at least an upper end of the batten. In certain embodiments, each latching member comprises one or more teeth configured for latching to a corresponding flange of the batten.
In embodiments of the cross rail, the upper wall comprises apertures for reception of a respective ceiling suspension clip such that the cross rail can be hung therefrom. Each aperture may comprise a slit configured to receive an engagement end of the suspension clip. In certain embodiments, each aperture may further comprise a central opening extending through the slit to permit rotation of the suspension clip about a longitudinal direction thereof relative to the cross rail.
In embodiments of the cross rail, the upper wall further comprises one or more openings associated with a respective aperture, each opening being configured to locate a corresponding projection of the suspension clip when inserted so as to retain an orientation of the cross rail relative to the suspension clip(s) from which it depends.
The present cross rail may be integrally formed. In one example, the cross rail may be formed from galvanised steel.
According to a second aspect of the present invention, there is provided a suspended ceiling system formed from:

- suspension rods;
- ceiling suspension clips secured to respective suspension rods;
- cross rails according to a first aspect of the present invention, the cross rails hanging from the suspension clips and being spaced apart in a transverse direction; and
- battens spanning across and being secured to two or more adjacent and spaced apart cross rails.

According to a third aspect of the present invention, there is provided a method of securing a batten to a cross rail according to a first aspect of the present invention, the batten comprising an elongate channel having opposed side walls, the method comprising:

- orienting the batten such that it is below the cross rail and substantially perpendicular thereto;
- urging the side walls of the batten toward one another such that a width of the urged batten is less than that between adjacent latching members;
- inserting at least an upper end of the side walls of the batten between adjacent latching members of two adjacent pairs of opposed latching members; and
- releasing said urging such that the side walls move away from one another and the batten is held in position between adjacent latching members.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1A is a top perspective view of a cross rail according to embodiments of the present invention;

FIG. 1B is a front view of the cross rail of FIG. 1A;

FIG. 2 is a side perspective view of two cross rails of FIG. 1A and two battens secured therebetween;

FIG. 3 is a close-up side view of a cross rail of FIG. 2 engaged with a batten;

FIG. 4 is a bottom perspective view of a batten secured to a cross rail according to embodiments of the present invention;

FIG. 5 shows cross rails according to embodiments of the present invention being used in both a ceiling and wall application, with battens secured thereto;

FIG. 6 is a top perspective view showing the cross rail FIG. 1A interconnecting a ceiling suspension rod and a batten;

FIG. 7 is a side perspective view of a ceiling suspension clip configured to engage a cross beam according to embodiments of the present invention;

FIG. 8 is a bottom perspective view of the clip of FIG. 7 ; and

FIG. 9 is a side view of the clip of FIG. 7 .

DETAILED DESCRIPTION

FIGS. 1A and 1B show a cross rail 6 according to embodiments of the present invention. The cross rail 6 is in the form of an elongate channel, having an upper wall 30 and a pair of opposed lateral walls 44 extending downwardly therefrom. As will be discussed, the upper wall 30 is configured for engagement with one or more ceiling suspension clips 2 such that the cross rail 6 can be supported thereby. The cross rail 6 also comprises pairs of opposed latching members 46 via which one or more battens 48 are securable to the cross rail 6. In the depicted embodiment, each latching member 46 of an opposed pair extends downwardly from a respective lateral wall 44.
FIGS. 2 to 4 show example battens 48 secured to the present cross rail 6. The depicted batten is an elongate furring channel 48 having a generally U-shaped cross section. The upper end of each side wall 50 of the furring channel comprises an outwardly projecting flange 52 extending along the length of the furring channel 48. An outer end 54 of each flange 52 curves downwardly such that the flange generally has a C-shaped cross section, the C facing downwards.
The present cross rail 6 is configured to releasably and adjustably secure the depicted furring channel 48 thereto. Referring to FIG. 4 , the cross rail 6 is held in place between two adjacent latching members 46 a of one lateral wall 44 a, and the corresponding and opposed adjacent latching members 46 b of the other lateral wall 44 b. As such, the batten 48 is securable substantially perpendicularly to the cross rail 6 between two adjacent pairs of opposed latching members 46 a, 46 b.
Referring to FIGS. 1A and 3 , each latching member is in the form of a downwardly projecting tab 46. At least one side of each tab 46 extends laterally outwardly (in the direction of the elongate cross rail) and carries an upwardly projecting hook-like tooth 56. Each tooth 56 is configured to be received in the C-shaped flange portion 54 extending outwardly from the side walls 50 of the furring channel 48, thereby latching to and under a respective flange 52. In other words, to secure a furring channel 48 to the cross beam 6, the furring channel 48 is inserted into a space 58 between adjacent latching members 46, wherein opposed teeth 56 of the adjacent latching members 46 locate and latch against respective elongate flanges 52 of the furring channel 48.
In certain embodiments, the width of the spacing 58 between adjacent latching members 46 may correspond to that of the furring channel 48 such that the channel 48 can be slotted along the longitudinal axis thereof between the latching members 46 without resistance therefrom. However, in such embodiments, the channels 48 may be vulnerable to inadvertent movement in the longitudinal direction thereof. As such, in other embodiments, a width of the space 58 between adjacent latching members 46 is narrower than that of the furring channels 48. In these embodiments, the side walls 50 of the furring channel 48 are first resiliently urged (e.g., squeezed) toward one another to reduce the width therebetween, thereby allowing the furring channel 48 to be moved vertically upwardly toward the cross rail 6 (rather than fed longitudinally) and inserted between adjacent latching members 46. Once inserted, the urging can be removed, thereby allowing the side walls 50 of the furring channel 48 to expand away from one another toward their original positions. However, during the expansion, the side walls 50 are obstructed by and thus abut and urge against respective adjacent latching members 46 of the cross rail 6, which urging helps to fix the position of the furring channel 48 relative to the cross rail 6. Advantageously, if a position of the furring channel 48 relative to the cross rail 6 is to be adjusted, one can simply urge the side walls 50 of the furring channel 48 together once again, thereby allowing for adjustment of the furring channel 48 along the longitudinal direction thereof relative to the cross rail 6.
The upper wall 30 of the cross rail 6 is configured to receive a suspension clip 2 so that the cross rail 6 can be hung therefrom. FIGS. 6 to 9 show an example ceiling suspension clip 2 configured to interconnect a suspension rod 4 and the cross rail 6. In use, an upper clipping portion 8 of the clip 2 is adjustably engaged with a downwardly extending suspension rod 4 of the ceiling system, and a lower portion 10 of the clip 2 is configured to engage with the cross rail 6 so that the rail 6 can hang from the clip 2. The lower portion 10 of the clip 2 is generally planar and comprises an engagement end 11 for securing to the cross rail 6.
The engagement end 11 is configured to be inserted through a correspondingly shaped aperture 22 of the cross rail 6 for engagement therewith. The engagement end 11 comprises a central portion 24 that extends downwardly from the centre of the planar lower portion 10 of the clip 2. The central portion 24 has a curvature along its length which extends out of the plane of the lower planar portion 10; this profile can provide the engagement end 11 with additional rigidity and strength so that it does not inadvertently detach from the lower planar portion 10 when loaded.
Extending laterally outwardly from the curved central portion 24 are a pair of tabs 26. The tabs 26 are in the same plane as that of the lower planar portion 10 but are vertically spaced from a bottom edge thereof. In this way, each tab defines an upper surface or edge 28 from which the cross rail 6 is configured to abut against and hang. To this end, the upper wall of the cross rail 6 comprises a series of spaced-apart apertures 22 configured to receive the engagement end 11 of the clip 2. The apertures 22 are shaped and sized to receive the generally planar engagement end 11 of the depicted clip 2. In particular, the apertures 22 comprise a central circular opening 32, sized to rotatably receive the curved central portion 24 of the engagement end 11. Extending outwardly from the circular opening 32 are a pair of slits 34, each sized to receive a respective planar tab 26 of the engagement end 11.
To engage the clip 2 with the cross rail 6, the clip 2 is moved into a first orientation wherein the lateral tabs 26 thereof are aligned with and can thus be inserted through the corresponding slits 34 of the cross rail 6. Once inserted, and with reference to FIG. 6 , the clip 2 is rotated about the longitudinal direction thereof into a second orientation wherein the tabs 26 are no longer aligned with the slits 34, and thus the engagement end 11 cannot be withdrawn from the cross rail 6. In the depicted example, the clip 2 is rotated approximately 90 degrees in the longitudinal direction thereof such that the plane of the tabs 26 is generally perpendicular to that of the slits 34 in the cross rail 6. This rotation of the inserted clip 2 is achieved via rotation of the curved central portion 24 thereof within the circular opening 32 of the aperture 22 in the cross rail 6. The space or clearance 36 between the tabs 18 and the planar lower portion 10 is sized to admit or receive the upper face 30 of the cross rail 6 adjacent to the apertures 22 thereof.
When the clip 2 is moved into the second orientation, as shown in FIG. 6 , the upper edge 28 of each tab 26 abuts against an interior surface of the upper wall 30 of the cross rail 6. Moreover, the weight of the cross rail 6, and any additional ceiling components that are attached thereto, cause the cross rail 6 to bear downwardly against and hang from the upper edges 28 of the tabs 18, thereby impeding against relative rotation between the cross rail 6 and the clip 2. In this way, the clip 2 cannot inadvertently escape or be withdrawn from the cross rail 6. Of course, if such withdrawal were desired, a user can raise the cross rail 6 slightly relatively to the clip 2 so that the cross rail 6 no longer bears downwardly upon the tabs 26, and then rotate the clip 2 back into the first orientation such that the engagement end 11 is aligned with the aperture 22 of the cross rail to permit withdrawal therefrom.
Referring to FIGS. 1 and 2 , the outer end of the upper edge 28 of each tab 26 is provided with an upwardly extending tooth or projection 38. Meanwhile, on opposite sides of each aperture 22 of the cross rail 6 are a pair of openings 40. When the engagement end 11 of the clip 2 is inserted into the cross rail 6 and rotated into position (as per FIG. 6 ), the projection 38 of each tab 26 is configured to be located in a respective one of the openings 40 in the cross rail 6; this location helps to further resist inadvertent relative rotation between the cross rail 6 and the clip 2 from which it hangs.
Many modifications of the above embodiments will be apparent to those skilled in the art without departing from the scope of the present invention. For example, with reference to FIG. 1A, it will be appreciated that the end latching members of the cross rail may simply have one tooth, whereas the inner or central tabs comprise two. The latching members may of course have other shapes and configurations, provided that they work to hold therebetween a batten. Preferably, the cross rail 6 is integrally formed from a material such as galvanised steel, though of course other constructions and materials are considered within the scope of the present specification.
The present cross rails 6 may also be used to form the frame of a wall. For example, with reference to FIG. 5 , certain cross rails 6 are shown clipped to a wall and extending vertically upwardly so as to function as a wall stud. The versatility of the cross rail in its ability to be used not only as ceiling components, but also wall components, provides opportunities for reducing the amount of material waste on-site, particularly when used in respect of multistory buildings. E.g., rather than having unused prior art cross rails or wasted offcuts thereof which need to be transported back down the multistory building for disposal, there are opportunities for cross rails 6 embodying the present invention to be utilised in other applications, such as in wall framing and the like.
Throughout this specification and the claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims

1. A cross rail to which one or more battens of a suspended ceiling system can be secured, the cross rail comprising:

an elongate channel having an upper wall via which one or more ceiling suspension clips are engageable to support the cross rail;

opposed lateral walls extending downwardly from the upper wall; and

pairs of opposed latching members via which one or more battens are securable to the cross rail, each latching member of a pair extending downwardly from a respective lateral wall such that, in use, a batten is securable substantially perpendicularly to the cross rail between two adjacent pairs of opposed latching members.

2. The cross rail of claim 1, wherein the latching members project downwardly from the lateral walls.

3. The cross rail of claim 2, wherein adjacent latching members are spaced apart from one another along a length of the lateral walls, which spacing is shaped and sized to receive at least an upper end of the batten.

4. The cross rail of claim 1, wherein each latching member comprises one or more teeth configured for latching to a corresponding flange of the batten.

5. The cross rail of claim 1, wherein the upper wall comprises apertures for reception of a respective ceiling suspension clip such that the cross rail can be hung therefrom.

6. The cross rail of claim 5, wherein each aperture comprises a slit configured to receive an engagement end of the suspension clip.

7. The cross rail of claim 5, wherein each aperture further comprises a central opening extending through the slit to permit rotation of the suspension clip about a longitudinal direction thereof relative to the cross rail.

8. The cross rail of claim 5, wherein the upper wall further comprises one or more openings associated with a respective aperture, each opening being configured to locate a corresponding projection of the suspension clip when inserted so as to retain an orientation of the cross rail relative to the suspension clip(s) from which it depends.

9. The cross rail of claim 1, wherein the cross rail is integrally formed.

10. The cross rail of claim 1, wherein the cross rail is made from galvanised steel.

11. A suspended ceiling system comprising:

suspension rods;

ceiling suspension clips secured to respective suspension rods;

cross rails, the cross rails hanging from the suspension clips and being spaced apart in a transverse direction; and

battens spanning across and being secured to two or more adjacent and spaced apart cross rails, wherein each of the cross rails comprise:

opposed lateral walls extending downwardly from the upper wall; and

12. A method of securing a batten to a cross rail the batten comprising an elongate channel having opposed side walls, the method comprising:

orienting the batten such that it is below the cross rail and substantially perpendicular thereto;

urging the side walls of the batten toward one another such that a width of the urged batten is less than that between adjacent latching members;

inserting at least an upper end of the side walls of the batten between adjacent latching members of two adjacent pairs of opposed latching members; and

releasing said urging such that the side walls move away from one another and the batten is held in position between adjacent latching members.