Patent Publication Number: US-8991120-B2

Title: Two-part channel cross member

Description:
BACKGROUND OF THE INVENTION 
     The invention relates to suspended ceiling construction and, in particular, to grid elements used with narrow utility channel systems. 
     PRIOR ART 
     Narrow channel systems are available for housing or otherwise locating various utility hardware in a conventional rectangular ceiling grid and tile construction. The channels are viewed as more harmonious or attractive than conventional arrangements for locating lights, air diffusers and returns, sprinklers and the like. Conventional arrangements, for example, dedicate a full grid module space to a single utility and, consequently, are more visually prominent than what is ordinarily needed to house a particular utility. The subject narrow channel systems, besides reducing the visibility of necessary utilities, can add to the attractiveness of a ceiling. 
     It is known to construct narrow utility channels by aligning a pair of conventional main runners or tees in close parallel relation. A number of inverted U-shaped yokes, spaced along the length of these main tees can be used to hold these main tees in parallel channel-forming relation at the ceiling plane. The yokes are located above the zone of the channel to provide space for utility hardware. This type of construction presents a need for a manner of trimming the ends of the hardware located in the channel such as panels, lights, grills or the like. Use of short cross runners or tees with conventional end connections for this purpose has proven to be difficult if not impractical. 
     SUMMARY OF THE INVENTION 
     The invention provides a cross member for narrow suspended ceiling channels which include a bulbous or three-dimensional lower flange. The cross member is useful for trimming the ends of typical utility components assembled in the channels while visually matching the profile of the surrounding suspended grid network. In accordance with the invention, a cross member with a three-dimensional lower flange can be constructed in two parts using a cross member carrier with a flat or two-dimensional flange and a three-dimensional cover. The preferred cover is arranged to be field mounted on the carrier after the carrier has been installed in the channel, typically in cross runner slots in main runners forming the channel. 
     The two-part cross member facilitates its assembly into a narrow channel because the visible three-dimensional cover part can be located with simple vertical motion onto the carrier part. Consequently, whereas the carrier part may require manipulation in a plane or planes to insert its ends in a pair of opposed cross runner slots, the three-dimensional cover part need not be subjected to the same. These separate installation steps can be, in total, less demanding in time and skill than what could be required if a single part was used. 
     In the disclosed embodiment, the carrier part has the shape of a conventional grid tee with an upper reinforcing bulb, a vertical web below the bulb, and a horizontal flange at a lower edge of the web. Advantageously, the end connectors are integrally stamped from the web material. The cover part is a U-shaped sheet metal channel stamping with out-turned narrow horizontal flanges on upper edges of the sides of the channel section. Local bendable tabs, integral with the flanges, are used to lock the cover in place on the carrier. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a fragmentary isometric view of a narrow ceiling utility channel in which the inventive two-part cross member is installed; 
         FIG. 2  is a side view of the two-part cross member taken in the plane  2 - 2  indicated in  FIG. 1 ; 
         FIG. 3  is a exploded perspective view of the two-part cross member; and 
         FIG. 4  is an end view of the two-part cross member. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  illustrates a narrow channel  10  formed of a pair of parallel main runners  11 . For visual harmony, the main runners  11  forming the channel  10 , as is typical, have the same visible cross-section as that of the grid members of a suspended ceiling in which the channel is integrated. This commonality is represented by cross runners  12  of the suspended ceiling that intersect the channel main runners  11 . The illustrated runners  11  and  12  are of the type disclosed in U.S. Pat. No. 8,359,801. The main runners  11  are elongated roll formed sheet metal members having an upper hollow reinforcing bulb  13 , a vertical web  14  and a flange  15 . The flange  15 , unlike a common grid tee flat or planar flange, is three-dimensional, having a U-shaped hollow center  17  and outwardly extending generally horizontal ribs  18 . 
     The main runner webs  14 , as is normal, have regularly spaced vertical slots  19  for receiving end connectors  21  of intersecting cross runners  12 . The opposed slots  19  of the main runners  11  are aligned with one another. The main runners  11  are held in spaced parallel alignment by suitable structure such as a plurality of longitudinally spaced inverted U-shaped yokes (only one is shown in  FIG. 1 ) outside and above the channel  10 . 
     Commonly, the narrow channel  10  is constructed before any cross members to be associated with it are installed. With the channel  10  being, for example, 4 inches or 6 inches wide, as measured center-to-center between the runners  11  (or their metric equivalent of 100 and 150 mm), installation of cross members  22  to trim the ends of utility hardware in the channel  10  can be problematic. 
     The present invention comprehends a two-part cross member  22 . A first part  23  of the cross member which serves as a carrier can have a conventional tee cross-section with a flat two-dimensional flange configuration. This description applies to the illustrated arrangement in  FIG. 4  where the flange, designated  24 , has two plies. One ply is made by the main body sheet which also forms an upper hollow reinforcing bulb  26 , and a web  27 . The second ply is formed by a cap sheet  28  having its longitudinal edges folded up into hems  29  over the longitudinal edges of the main body sheet flange ply. 
     The carrier  23  can be formed by cutting short lengths of regular cross tee stock. The carrier  23  can have integral end connectors  30  stamped out of the web area of the tee stock. 
     The other cross member part is a cover  31  having a shape of the lower visible face of the main runners  11  forming the channel  10  (as well as the cross tees or runners  12 ). Referring to  FIG. 3 , the cover  31 , formed of malleable sheet metal, has a U-shaped center  32  and narrow outwardly directed upper ribs  33 . At each end, the center section  32  projects axially beyond the ribs or flanges  33  a distance equal to the width of the ribs. At each end of a rib  33 , the cover  31  has an integral rectangular tab  34 . The cover  31  can be supplied to the installer with the tabs  34  upstanding as shown in  FIG. 3 . 
     In accordance with the invention, the carrier  23  of the cross member  22  is fully installed in the channel  10  before the cover  31  is assembled. In reference to  FIG. 1 , the installation of the carrier  23  can begin with insertion of one end connector  30  into a selected cross runner slot  19 . The opposite or second end connector  30  can be bent to foreshorten the carrier  23  and enable it, with the one end connector  30  fully inserted in a cross runner slot  19 , to fit between the main runner webs  14  of the channel  10 . The carrier end connectors  30  are proportioned with respect to the main runner slot  19  to support the carrier flange  24  in a common plane with the main runner flanges  15 . The length of the carrier flange  24  is proportioned so that its end edges abut longitudinal edges of the main runner flanges  15 . When the carrier  22  is diagonally disposed in the channel  10  at the beginning of its assembly in the channel, the corners of its flanges  24  can be resiliently deflected so as to overlie and slide over the main runner flanges  15  to the extent necessary. 
     With the second end connector  30  fully received in its respective slot  19 , the cover  31  is assembled on the carrier  23 . This is accomplished by aligning the cover  31  below the carrier  23  and raising it vertically between the channel main runners  11  until its ribs  33  abut the carrier flange  24 . 
     The ends of the cover center  32  are proportioned to fit below the main runner ribs  18  and abut the vertical side of the flange centers  17 . When the cover  31  is properly positioned, the tabs  34  are manually bent inwardly over the carrier flange  24  to lock the cover  31  in place on the carrier  23 . It will be understood from the foregoing that the cover  31  fits in place without extraneous manipulation that would risk scratching the visible painted sides of the main runner flange center  17 . 
     The selected position of a cross member  22  will correspond to the end of a utility device or panel requiring a finished or integrated look and usually will be in line with a pair of cross runners  12 . Note that the slots  19  are wide enough to receive the end connectors  21  of the cross runners as well as the end connectors  30  of the cross member carrier  23 . Thus, the cross member  22  will continue the visual line transversely across the channel  10 . 
     It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. 
     The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.