WO2018187660A1

WO2018187660A1 - Suspended ceiling beam with a reinforced bulb

Info

Publication number: WO2018187660A1
Application number: PCT/US2018/026415
Authority: WO
Inventors: Hanhui Li
Original assignee: Worthington Armstrong Venture
Priority date: 2017-04-07
Filing date: 2018-04-06
Publication date: 2018-10-11
Also published as: US20180291622A1

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.

Description

SUSPENDED CEILING BEAM WITH A REINFORCED BULB

RELATED APPLICATION

[0001] This application claims the benefit of priority to U.S. Provisional Patent Application Serial Number 62/482,726, filed on April 7, 2017, and U.S. Non-Provisional Patent Application Serial Number 15/946,760, filed on April 6, 2018, the contents of which are incorporated in this application by reference.

FIELD OF THE INVENTION

[0002] This disclosure relates generally to the field of beams that are roll-formed from sheet metal and that comprise the grid of suspended ceilings and, more specifically, beams with a bulb that contains at least one reinforcing pleat, which increases the structural load capacity of the beam.

BACKGROUND OF THE DISCLOSURE

[0003] Relatively light roll-formed sheet metal beams currently used to comprise the grid of a suspended ceilings are shown, for instance, in U.S. Patent No. 5,979,055 and No. 6,138,416. Typically, such light beams are arranged into a grid, as shown, for instance, in U.S. Patent No. 6,763,642. The grid supports panels, which provide a pleasing cover over a room, with minimal use of metal in the grid beam. This minimization of metal also minimizes the structural load capacity of the beam. As a result, although the beams are not typically subjected to additional structural loads, when the beams are subjected to an additional structural load the load is a lightweight load, such as the loads shown in U.S. Patent No. 3,612,461 (a light fixture), or U.S. Patent No. 4,073,458 (an advertising sign).

[0004] Where it is necessary to support heavier structural loads, such as data banks, from a suspended ceiling, heavy forged metal beams are typically incorporated into the ceiling grid in place of the light roll-formed sheet metal beams described above. The incorporation of forged metal beams increases costs and installation times as the forged metal beams contain more material than the roll-formed beams and the installer must switch back and forth between the installation of two types of beams.

[0005] Therefore, there exists a need for a roll-forged beam with increased load capacity, which does not use significantly more material.

BRIEF SUMMARY OF THE DISCLOSURE

[0006] To meet this and other needs, and in view of its purposes, a roll-formed steel beam with a bulb that contains at least one pleat is provided. In one embodiment, this pleated bulb increases structural load capacity by over twenty percent (20%), while only using about twelve percent (12%) more material then prior designs. Furthermore, this beam can be installed in the same manner as prior roll-formed beams.

[0007] The disclosed beam is comprised of: (1) a web having a top and a bottom edge opposite each other; (2) two flanges opposite each other at the bottom edge that each extend out in a substantially perpendicular angle from the web; and (3) a bulb, which contains at least one pleat, at the top of the web. Typically, the pleat will be on the top of the bulb so as to provide the greatest increase to the load capacity.

[0008] The beam may also be incorporated into a ceiling system to form a suspended support grid which includes a plurality of intersecting grid support members arranged horizontally with grid openings formed between the grid support members. The suspended ceiling grid formed from the beams is suspended from a structural support, such as a structural ceiling, by hang wires. [0009] In one embodiment, threaded load and hang rods are secured to a suspended ceiling grid formed from the disclosed beam by clips shaped to transmit loads in a substantially vertical manner through the webs of the beams while minimizing the twisting and/or bending of the beams. The load and hang clips are spaced on the suspended ceiling at locations that maintain a level and balanced suspended ceiling. Lower threaded load rods may be secured to the beams with load clips in a manner that passes the loads vertically upward through the webs of the beams to grid beam hang clips, at selected ceiling locations on the grid, above the suspended ceiling. The grid beam hang clips receive and pass the load through the suspended ceiling to upper threaded rods, above the suspended ceiling, that are secured into the upper structural support, again, such as a support ceiling.

[0010] A method for forming the beams is provided. The method includes providing flat coil stock that is fed into a series of rollers which: (1) draws the stock to the centerline to form a pleat; (2) flattens the pleat; (3) applies a zigzag to each half of the stock to form the bottom of the bulb and the top edge of the web; (4) bends the edge of each side of the stock approximately ninety degrees (90°) to produce a flange; (5) folds the stock down the centerline; and (6) stiches the web together forming the beam.

[0011] It is to be understood that both the foregoing general description and the following detailed description are exemplary, but are not restrictive, of the invention.

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. Patent 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. Patent 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 :

[0052] Table 1

[0053] 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): [0054] Table 2

[0055] 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):

[0056] Table 3

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

[0057] The result of the two failure tests on Beam B are outlined in Table 4 below where deflection is measured in inches (cm): [0058] Table 4

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

[0059] The results of the three failure tests on Beam C are outlined in Table 5 below where deflection is measured in inches (cm): [0060] Table 5

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

[0061] 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).

[0062] 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.

Claims

CLAIMS What is claimed is:

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 stich 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 stich 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.