Patent Publication Number: US-2023160203-A1

Title: Suspended drywall ceiling grid system support members

Description:
BACKGROUND 
     The present invention relates to grid systems for ceilings and more particularly to suspended drywall ceiling grid system support members. 
     Suspended drywall ceilings typically require a support grid comprising a plurality of interconnected support members for installation of drywall sheets. The support members typically are of two types, which often are referred to as runners and cross tees. The runners and cross tees also may be referred to as beams, tees or grid tees, and typically have a generally inverted T-shape. A vertical web generally extends downward to opposed horizontal flanges. The flanges receive self-tapping drywall screws, to support drywall sheets. Connected lengths of the runners generally are arranged in a parallel and spaced apart configuration. The cross tees generally tend to be constructed similarly to the runners and arranged in a parallel and spaced apart configuration that is perpendicular to and spanning the distance between the runners. 
     The support members tend to be made in roll-forming operations in which a flat strip of sheet metal is sequentially deformed into an inverted T-shape. The support members may but need not be symmetrical in cross-section about a vertical axis. The opposed flanges may have a single flat layer of sheet metal, may have an outer portion of the flange bent backward onto itself to create a double thickness forming a hem, or the flanges may be covered by a cap, which provides a second layer of sheet metal across the flanges. Any of these configurations tend to include sharp sheet metal edges along the flanges, which present a hazard to an installer when grasping a support member. 
     Once the support members, including runners and cross tees are installed in an assembled, suspended configuration, a drywall installer brings a drywall sheet up to the grid for installation. However, the installer approaches from below the drywall sheet when seeking to install a screw to secure the drywall sheet to the grid. In such a position, the installer generally may not be able to see the support members that are above the drywall sheet. For proper and secure installation, a rotating self-tapping screw having a threaded shaft must pass through the drywall, engage and pierce one of the opposed flanges of the support member, and threadably draw the drywall upward against the support member. Unfortunately, the screw may engage the flange near an outer edge or wander on the flange toward the outer edge and tear through the outer edge, bend the outer edge of the flange upward without piercing the flange, or simply move off the outer edge of the flange without piercing and threadably engaging the flange. 
     SUMMARY 
     By way of the present disclosure, a suspended drywall ceiling grid system includes support members in the form of runners and cross tees that may be assembled or connected to each other in a grid to support panels, such as drywall sheets. The new support members provide a combination of structural features that provide enhancements. 
     The new support member structures provide for safer and more convenient handling of the runners and cross tees by preventing inadvertent contact with sharp sheet metal along the outer edges of the opposed flanges. The outer edges of the flanges are configured to advantageously provide the flanges with increased strength and resistance to upward bending, while also providing the support members increased overall rigidity. The new support member structures additionally provide screw stops, which reduce the potential for a self-tapping screw to wander, move off or tear through an outer edge of a flange. The unique screw stop flange structure provides a further benefit by alleviating a need for a cap or additional layer of sheet metal over the flanges. As a result, the support members advantageously are economical to manufacture, convenient and safer to handle, with screw stops that enhance the likelihood that a self-tapping screw will pierce and threadably penetrate a flange to securely connect a drywall sheet to the grid. 
     A support member in the form of a runner or cross tee of the present disclosure has a cross-section generally in the form of an inverted T-shape. A central web has a double thickness of sheet metal. A pair of drywall support flanges extend from a lower portion of the central web in opposite directions, and a reinforcing bulb extends from an upper portion of the central web. 
     In a first aspect, a support member for a suspended drywall ceiling grid system of the present disclosure includes a central web formed of two layers of sheet metal having first and second ends. A reinforcement bulb extends from an upper portion of the central web between the first and second ends. Opposed flanges extend from a lower portion of the central web between the first and second ends. First and second end connectors are integral with the central web and extend from the first and second ends of the central web, respectively, past the flanges. Each of the opposed flanges has an upper surface and a knurled lower surface between the central web and a rolled edge portion, and each rolled edge portion has an initial region tilted downward and outward and extends into a curved region, wherein the curved region is rolled upward and inward and terminates in an outer edge toward the initial region. 
     The first and second connectors on support members that are runners facilitate end-to-end attachment of a first runner to a second runner. The first and second connectors on support members that are cross tees similarly facilitate end-to-end attachment of a first cross tee to a second cross tee, and such end connectors on cross tees are configured to connect to a runner by extending through an aperture in the runner. 
     The first end connector of a support member is displaced out of a plane defined by the central web in a first direction and the second end connector is displaced out of the plane defined by the central web in a second direction opposite to the first direction, with each of the first and second end connectors having a distal edge. A strap adjacent each end of the central web is deformed out of the plane defined by the central web in a direction opposite to the adjacent end connector. Each strap is configured to receive an end portion of an end connector of a similar support member. 
     Other features and advantages will become apparent upon reference to the drawings and detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In describing the preferred embodiments, reference is made to the accompanying drawing figures wherein like parts have like reference numerals, and wherein: 
         FIG.  1    is a perspective side view of a first example support member for a suspended drywall ceiling grid system in the form of a runner in accordance with the present disclosure. 
         FIG.  2    is a side view of the first example support member of  FIG.  1   . 
         FIG.  3    is a top view of the first example support member of  FIG.  1   . 
         FIG.  4    is a bottom view of the first example support member of  FIG.  1   . 
         FIG.  5    is an end view of the first example support member of  FIG.  1   . 
         FIG.  6    is a cross-sectional view of the first example support member of  FIG.  1   . 
         FIG.  7    is a lower perspective view of the first example support member of  FIG.  1     
         FIG.  8    is an end view of the first example support member of  FIG.  1    showing a first screw centrally located relative to the left flange and a second screw captured at the outer edge as it pierces through the right flange. 
         FIG.  8 A  is an enlarged view of the second screw captured at the outer edge as it pierces through the right flange of the first example support member of  FIG.  8   . 
         FIG.  9    is a perspective side view of a second example support member for a suspended drywall ceiling grid system in the form of a cross tee in accordance with the present disclosure. 
         FIG.  10    is a side view of the second example support member of  FIG.  9   . 
         FIG.  11    is a top view of the first example support member of  FIG.  9   . 
         FIG.  12    is a bottom view of the second example support member of  FIG.  9   . 
         FIG.  13    is an end view of the second example support member of  FIG.  9   . 
         FIG.  14    is a cross-sectional view of the second example support member of  FIG.  9   . 
         FIG.  15    is a partial upper perspective view of an assembly of two of the second example support members of  FIG.  9    connected to two of the first example support members of  FIG.  1   . 
         FIG.  16    is a cross-sectional side view of a connected assembly of the ends of two of the second example support members of  FIG.  9    extending through an aperture in one of the first example support members of  FIG.  1   . 
         FIG.  17    is a cross-sectional top view of the connected assembly of  FIG.  16   . 
         FIG.  18    is a partial upper perspective view of an assembly of three of the second example support members of  FIG.  9    connected to one of the first example support members of  FIG.  1    for a suspended ceiling grid system, and an example drywall sheet is raised to the underside of the grid system, in accordance with the present disclosure. 
         FIG.  19    is a partial lower perspective view of an assembly of a drywall sheet secured to five of the second example support members of  FIG.  9    that are connected to one of the first example support members of  FIG.  1   , in accordance with the present disclosure. 
         FIG.  20    is a partial upper perspective view of an assembly of ten of the second example support members of  FIG.  9    connected to two of the first example support members of  FIG.  1    for a suspended ceiling grid system, and two example drywall sheets are raised to the underside of the grid system, in accordance with the present disclosure. 
     
    
    
     It should be understood that the drawings are not to scale. While some mechanical details of example support members for a suspended drywall ceiling grid system, including other plan and section views of the examples shown and of examples that may have alternative configurations, have not been included, such details are considered within the comprehension of those of skill in the art in light of the present disclosure. It also should be understood that the present invention is not limited to the example embodiments illustrated. 
     DETAILED DESCRIPTION 
     With reference to  FIGS.  1 - 20   , preferred embodiments of suspended drywall ceiling grid systems are provided. In  FIG.  1   -8a, a first example support member  2  for a suspended drywall ceiling grid system is shown. The first example support member  2  includes a central web  4  formed of two layers  6 ,  8  of sheet metal having first and second ends  10 ,  12 . A reinforcement bulb  14  extends from an upper portion  16  of the central web  4  between the first and second ends  10 ,  12 . Opposed flanges  18 ,  20  extend from a lower portion  22  of the central web  4  between the first and second ends  10 ,  12 . First and second end connectors  24 ,  26  are integral with the central web  4  and extend from the first and second ends  10 ,  12  of the central web  4 , respectively, past the flanges  18 ,  20 . The central web  4  includes vertically extending apertures  70  that may receive end connectors of respective first and second cross tees  102 ,  102 , as will be described further herein. 
     Each of the opposed flanges  18 ,  20  has an upper surface  28  and a knurled lower surface  30  between the central web  4  and a rolled edge portion  32 ;  34 . Each rolled edge portion  32 ,  34  has an initial region A tilted downward and outward and extending into a curved region B, wherein the curved region B is rolled upward and inward and terminates in an outer edge  36 ,  38  toward the initial region A. 
     It will be appreciated that the first example support member  2  may be configured, for example, to be a runner for use in a suspended drywall ceiling grid system. 
     In  FIGS.  9 - 14   , a second example support member  102  for a suspended drywall ceiling grid system is shown. The second example support member  102  includes a central web  104  formed of two layers  106 ,  108  of sheet metal having first and second ends  110 ,  112 . A reinforcement bulb  114  extends from an upper portion  116  of the central web  104  between the first and second ends  110 ,  112 . Opposed flanges  118 ,  120  extend from a lower portion  122  of the central web  104  between the first and second ends  110 ,  112 . First and second end connectors  124 ,  126  are integral with the central web  104  and extend from the first and second ends  110 ,  112  of the central web  104 , respectively, past the flanges  118 ,  120 . The central web  104  includes vertically extending apertures  170  that may receive end connectors of respective first and second cross tees  102 ,  102 , as will be described further herein. 
     Each of the opposed flanges  118 ,  120  has an upper surface  128  and a knurled lower surface  130  between the central web  104  and a rolled edge portion  132 ,  134 . Each rolled edge portion  132 ,  134  has an initial region A′ tilted downward and outward and extending into a curved region B′, wherein the curved region B′ is rolled upward and inward and terminates in an outer edge  136 ,  138  toward the initial region A′. 
     The second example support member  102  may be configured to be a cross tee, for example, for use with the first example support member  2  in the form of a runner in a suspended drywall ceiling grid system. 
     Thus, it will be appreciated that a support member may be a runner  2  or cross tee  102 , which share many similarities in construction and configuration and may be configured to be connected together to form a grid system. As may be seen in  FIGS.  9  and  10   , the cross tee  102  includes raised portions  140 ,  142  at the ends of the flanges  118 ,  120 . The raised portions  140 ,  142  near the ends of the flanges  118 ,  120  of the cross tee  102  may rest upon the flanges  18 ,  20  of respective runners  2  (or may rest upon the flanges  118 ,  120  of respective cross tees  102 ) to which the cross tees are connected. The raised portions  140 ,  142  help to present a common lower plane of the system grid, while also providing additional vertical support of the cross tees  102 . 
     Each rolled edge portion  32 ,  34 ,  132 ,  134  of the respective flanges  18 ,  20 ,  118 ,  120  of the respective support members  2 ,  102  provides a screw stop. Structural rigidity, convenience and safety in handling the respective support member  2 ,  102  are established by having the curved region B, B′ of each respective rolled edge portion  32 ,  34 ,  132 ,  134  terminate in contact with the respective initial region A, A′. Protection from the respective sharp sheet metal outer edge  36 ,  38 ,  136 ,  138  of each respective flange  18 ,  20 ,  118 ,  120  also is facilitated by each respective rolled edge portion  32 ,  34 ,  132 ,  134  having a top of the respective curved region B, B′ generally coplanar with the respective upper surface  28 ,  128  of the respective flange  18 ,  20 ,  118 ,  120 . The configuration of the respective rolled edge portion  32 ,  34 ,  132 ,  134  also provides for favorable mating of the upper surface of a drywall sheet to the respective lower surface  30 ,  130  of the respective flange  18 ,  20 ,  118 ,  120 , with relatively little or no flange deformation occurring at screw locations. 
     Each respective support member  2 ,  102  has a cross-section generally in the form of an inverted T. Strength and rigidity are enhanced in each respective support member  2 ,  102  by a first row of longitudinally spaced stitches  44 ,  144  at the respective upper portion  16 ,  116  of the respective central web  4 ,  104  adjacent the respective bulb  14 ,  114  and a second row of longitudinally spaced stitches  46 ,  146  at the respective lower portion  22 ,  122  of the respective central web  4 ,  104  adjacent the respective flanges  18 ,  20 ,  118 ,  120 , with the stitches  44 ,  144  in the first row being staggered relative to the stitches  46 ,  146  in the second row. 
     Each of the first and second end connectors  24 ,  26  of the support member  2  further includes a locking tab  48 ,  50 . Each of the ends  10 ,  12  of the central web  4  further includes a strap  52 ,  54  deformed out of the plane defined by the central web  4  and being located adjacent the respective end connector  24 ,  26 . It will be appreciated that when a similar support member  2  is placed in end-to-end engagement, the respective straps  52 ,  54  receive the respective end connectors  24 ,  26  and engage the respective locking tabs  48 ,  50 . This is shown with respect to the support members  2  configured as runners. 
     In the alternative embodiment showing a support member  102  in the form of a cross tee, each of the first and second end connectors  124 ,  126  of the support member  102  further includes a tab  156 ,  158  extending in a first direction and being configured to engage the central web  4  of a separate perpendicularly disposed support member  2 , or a central web  104  of a separate perpendicularly disposed support member  102 . This may be best appreciated when viewing  FIGS.  9  and  15 - 17   . Each of the first and second end connectors  124 ,  126  of the support members  102  placed in end-to-end engagement further includes a locking tab  160 ,  162  extending in a second direction opposed to the first direction of the respective tabs  156 ,  158 , and when said support member  102  and a similar support member  102  are placed in end-to-end engagement with the respective end connectors  124 ,  126  extending through an aperture  70  in a central web  4  of a separate perpendicularly disposed support member  2  (or through an aperture  170  in a central web  104  of a separate perpendicularly disposed support member  102 ), the respective locking tabs  160 ,  162  engage an edge of the area punched out to form tabs  156 ,  158 . Thus, a runner  2  having an aperture  70  through the central web  4  (or a cross tee having an aperture  170  through the central web  104 ) receives end connectors  124 ,  126  of respective first and second cross tees  102 ,  102  that connect to each other, such as by respective locking tabs  160 ,  162  engaging the edges in the respective punch outs for tabs  156 ,  158 . 
     It will be appreciated that the knurled lower surface  30  of the support members  2 , best seen in  FIG.  7   , helps to prevent a self-tapping screw from wandering across the lower surface  30  of the flanges  18 ,  20 . It will be appreciated that the knurled lower surface  30  of the flanges  18 ,  20  would result in a visible pattern on the upper surface of the flanges, but this is not shown, so as to improve the ease of viewing other features in the figures. The lower surface  130  of the support members  102  also may include the advantageous knurled surface to limit wandering of a screw. However, the knurled lower surface and corresponding pattern that would be on the upper surface of the flanges of the support member  102  also are not shown in the figures, so as to improve the ease of viewing other features of the support members. Thus, both support members  2 ,  102  may include flanges having knurled lower surfaces to help prevent screws from wandering across or along the lower surface of a flange. 
     As further shown in  FIGS.  8  and  8   a   , the unique rolled edge portion  34  of the flange  20  of support member  2  (representative of the rolled edge portions  32 ,  34 ,  132 ,  134  of the respective flanges  18 ,  20 ,  118 ,  120 ) is particularly helpful with respect to increasing the likelihood of stopping a self-tapping screw from wandering off an outer edge of a flange. In fact, the added rigidity of the rolled edge portion  34  resists having the screw S bend the outer edge upward, which would otherwise potentially permit the screw to avoid piercing the flange  20 . 
     In addition, having the outer edge  38  of the flange  20  curl downward, outward, upward and then inward first results in the rolled edge portion  34  biasing a rotating screw S to stay on and pierce the flange  20 . This structure also provides an added barrier to prevent tear through of the outer edge  38  of the flange  20  because if the screw S pierces the flange  20 , the outer edge  38  itself provides final biasing of the screw S to stay within the flange  20  as it pierces the flange  20  and threadably secures a drywall sheet to the flange  20  of the support member  2 . It will be appreciated that the structure of this advantageous screw stop feature is able to be utilized with both the support members  2 ,  102  and their respective flanges  18 ,  20 ,  118 ,  120 , so as to provide well connected, relatively rigid runners and cross tees that are likely to yield a higher percentage of successful screw to flange engagements during installation. 
       FIGS.  16 - 17    illustrate cross-sectional side and top views of an intersection of a pair of cross tees  102  and a single runner  2 , which may commonly be found in an assembly of a suspended drywall ceiling grid. The connector ends  124 ,  126  that are connected to the central webs  104  of the cross tees  102  extend through an aperture  70  in the central web  4  of the runner  2 , to thereby connect the three support members. The views show that the raised portions  140 ,  142  of the respective flanges  118 ,  120  of the cross tees  102  rest atop the flanges  18 ,  20  of the runner  2 . 
     It will be appreciated that many configurations for use as a suspended drywall ceiling grid system may be utilized by combining the support members  2 ,  102  disclosed herein, while providing consistent structural integrity and superior screw engagement. A few representative views of grid systems and relative drywall placement are provided in  FIGS.  18 - 20   . For example,  FIG.  18    shows a partial upper perspective view of an assembly of three of the example support members  102  in the form of cross tees that are connected to one example support member  2  in the form of a runner as part of a suspended ceiling grid system. In this example, a drywall sheet D is located in a raised position where it is adjacent the underside of the grid system, in contact with the lower surface  30 ,  130  of the support members  2 ,  102 . The end connectors  124 ,  126  of the support members  102  extend through apertures  70  to connect to the support member  2  to be held in engagement with the support member  2  by tabs  156 ,  158 , and held in engagement with each other by locking tabs  160 ,  162 . 
       FIG.  19    provides a partial lower perspective view of an assembly of a drywall sheet D secured by screws S to five example support members  102  that in turn are connected to one example support member  2 . 
     It will be appreciated that  FIG.  20    is a further partial upper perspective view of an assembly of ten of the example support members  102  that are connected to two of the example support members  2  for use as a portion of a suspended ceiling grid system. In this view, two example drywall sheets D have been raised to the underside of the grid system, with each spanning the distance between five support members  102 . The drywall sheets would be brought into contact with the lower surface  30 ,  130  of the support members  2 ,  102  for installation of screws to secure the drywall sheets D to the grid system. 
     Thus, improved support members for use in a suspended drywall ceiling grid system have been provided. While the support members have been described in terms of certain preferred embodiments, there is no intent to limit the invention to the same. Instead, the invention is defined by the scope of the following claims.