AU2006201389B2

AU2006201389B2 - Attachment System for a Suspended Ceiling

Info

Publication number: AU2006201389B2
Application number: AU2006201389A
Authority: AU
Inventors: Raymond Phillip CRANE
Original assignee: CRANE IP Pty Ltd
Current assignee: CRANE IP Pty Ltd
Priority date: 2005-04-05
Filing date: 2006-04-04
Publication date: 2009-12-10
Anticipated expiration: 2026-04-04
Also published as: AU2006201389A1

Description

ATTACHMENT SYSTEM FOR A SUSPENDED CEILING Field of the Invention. The present invention relates to suspended ceilings and in particular to an attachment system for a suspended ceiling which allows increased utility. 5 Background Art. Suspended ceilings are hung from the ceiling joists with a metal grid. This creates the cavity between the joists and the ceiling where pipes, wires, and ductwork can be installed and worked on. A tile ceiling is either glued directly to an existing ceiling or onto "furring strips" that are glued or nailed or otherwise attached 10 to the existing ceiling. This type of ceiling works well either in covering over an older existing ceiling or where height is a consideration and a suspended ceiling would drop too low. The main Australian Standard that must be dealt with whilst dealing with suspended ceilings is AS 2785 - 1985 : Suspended ceiling design and 15 installation. This Australian Standard deals with things such as the strength of the whole system, fire resistance, the Acoustic properties of the system, as well as other factors like ventilation, the quality of workmanship and many other things. ASTM C636-91 standard specification for metal suspension systems for acoustical tile and lay in panels deals specifically with the design and manufacture 20 of tiles and lay in panels for the modular systems. Other Standards that relate to suspended ceiling systems are AS 2588 1983 relating to plasterboard products and AS 1538 - 1985 cold formed steel structures code which deals with how the suspended ceiling frame is manufactured. Suspended and tile ceilings have several advantages. The greatest of 25 these is weight. The ceiling is the only area of the room where gravity imposes a restriction on the weight of material used. Installing and securing heavy ceiling materials (such as drywall) can be difficult. A suspended ceiling is one which is not directly fixed to the roof structure above it but as its name implies is suspended by the means of metal rods and channels. They are easy to install and secure because of their 30 relatively low weight The actual metal used in the suspended ceiling frame is either galvanized metal or extruded aluminium, while the sheets are either of a flush, flat surface or in the case of infill panels can be perforated or powder coated metal or like the plasterboard sheets have a smooth finish. Also, many types absorb sound and 2 thereby add to the sound control of the room. It comes in many different styles, sizes, and colors and is easily obtainable from any home center or hardware store. There are four key parts of a suspended ceiling system: * Main runners or top cross rails, the primary support members, are arranged in 5 parallel rows that run the length of the room. Main runners come in a variety of finishes and shapes but are usually suspended from the purlins in the roof structure. " Cross runners or furring channels are lighter-gauge supports that attach to the top cross rails at right angles. 10 * Hangers are lengths of lightweight wire or cable. One end of each hanger attaches to the top cross rail, while the other end attaches to the purlins. * Ceiling panels are attached to the grid created by the furring channels. The panels can be square or rectangular and come in a variety of sizes and patterns. One limitation of the existing suspended ceiling systems is that clips 15 are used to attach each of the furring channels to each of the top cross rails. These clips only allow a perpendicular attachment of the furring channels to the top cross rails. This creates problems in that the installer of the suspended ceilings is not able' to easily extend the furring channels into "hips" or "valleys" where the ceiling design requires it. Further, the perpendicular only orientation of the furring channels make 20 them difficult to use when installing ceilings with curves or to the limit of bulkheads when installed. It is further difficult to maintain level ceiling lines fro applying beading at ceiling junctions, hips and valleys which results in an increased labour cost and a waste of materials. It will be clearly understood that, if a prior art publication is referred to 25 herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country. Summary of the Invention. The present invention is directed to an attachment system for a suspended ceiling, which may at least partially overcome at least one of the 30 abovementioned disadvantages or provide the consumer with a useful or commercial choice.

3 In a first form, the invention resides in a mounting clip for attaching a first ceiling member relative to a second ceiling member in a suspended ceiling system, the mounting clip including a. a first ceiling member attachment portion and 5 b. a second ceiling member attachment portion wherein the respective attachment portions of the mounting clip are pivotable with respect to one another. The mounting clip of the present invention allows the angle between the first ceiling member and the second ceiling member to be adjusted to an angle 10 other than 90. This provides not only an increased functionality when installing the suspended ceiling particularly with regard to the configurations of ceilings possible but also increases efficiency in materials used and time of the installation. The first and second ceiling members will typically be what are known in the trade as a "top cross rail" and a "furring channel". 15 Each of these members is typically manufactured of a light metal or plastic material and usually, a galvanised. metal is used. Each member usually has a substantially U-shaped cross-section with one or more flange portions or dimension changes to allow the members to be attached to clips or brackets. Alternatively, the furring channels may be installed extending between the top cross rails to form a two 20 dimensional grid with a plurality of top cross rails extending perpendicularly to a plurality of furring channels. Each furring channel is typically a substantially U-shaped channel member having a base wall and two spaced apart sidewallsextending from the base wall. Each of the sidewalls has a free end, adjacent to which is typically a laterally 25 extending flange member which may be used to attach the furring channel relative to a top cross rail. The flange members typically extend outwardly from the respective side walls and usually a mounting clip member engages the flange members. Each top cross rail is also typically a substantially U-shaped channel member having a base wall and two spaced apart sidewalls extending from the base 30 vall. When viewed in cross-section, the sidewalls of the member are provided with a narrower "waist" section located between a wider shoulder portion and a wider "hip" portion. The waist portion generally allows the attachment of a. suspension bracket, 4 which is typically provided at an end of a wire or cable suspended from a roof member. The wider shoulder portion carries the weight of the rail and the associated ceiling system. 5 The wider hip portion generally comprises a lateral channel of each side wall. Each lateral channel is preferably adapted to receive a correspondingly shaped portion of a mounting clip therein to attach the top cross rail member to the furring channel member. Generally, at least a part of the mounting clip may be received in the U-shaped channel of the top cross rail with protuberances of the 10 mounting clip being received in each lateral channel. In a second form, the invention resides in an attachment system for a suspended ceiling including a. at least one cross rail member suspended from a roof member, b. at least one furring channel member to which one or more ceiling members are 15 attachable, and at least one mounting clip for mounting the at least one cross rail member relative to the at least one furring channel, the mounting clip including i. a cross rail member attachment portion and ii. a furring channel member attachment portion 20 wherein the respective attachment portions of the mounting clip are pivotable with respect to one another. The mounting clip of the present invention is adapted to allow the secure attachment of at least one cross rail member to or relative to at least one furring channel whilst allowing the members to rotate with respect to one another. 25 The mounting clip of the present invention includes a first ceiling member attachment portion. Typically, the first ceiling member may be a cross rail member and therefore the first ceiling member attachment portion will generally engage with the cross rail. Preferably, the first ceiling member attachment portion will have 30 shaped portions adapting it for engagement with-the hip portion or lateral channels of the top cross rail as described above. The shaped portions are preferably protuberances which extend from the first ceiling member attachment portion and are received within the lateral channels of the top cross rail.

5 The first ceiling member attachment portion will typically be substantially U-shaped with a base wall and a pair of spaced apart sidewalls. The sidewalls will typically be slightly resilient and outwardly diverging adapting the sidewalls to apply force to the shaped portions to maintain the shaped portions in the 5 lateral channels of the top cross rail. The slight resilience may also give the first ceiling member attachment portion a snap-fitting action when assembling the attachment system. The first ceiling member attachment portion may alternatively be slideable with respect to the lateral channels. Suitably, the first ceiling member attachment portion will be provided 10 with a single, substantially centrally positioned, shaped portion on a first sidewall and a pair of spaced apart shaped portions in a second sidewall. This may act to allow easier assembly of the first ceiling member attachment portion into the lateral channels and/or adjustable movement along the lateral channels of a cross rail. The base wall of the first ceiling member attachment portion may be 15 provided with one or more openings therein to and a pivot member will typically be associated with the opening to allow the respective attachment portions of the mounting clip to pivot or rotate with respect to one another. The mounting clip of the present invention also includes a second ceiling member attachment portion. Typically, the second ceiling member may be a 20 furring channel member and therefore the second ceiling member attachment portion will generally engage with the furring channel. Preferably, the second ceiling member attachment portion will have at least one and typically a pair of shaped portions adapting it for engagement with the laterally extending flange members of the furring channel as described above. The 25 shaped portions are preferably tab members which extend from the second ceiling member attachment portion and lockingly engage with the flange -iembers. The second ceiling member attachment portion will typically be substantially U-shaped with a base wall and a pair of spaced apart sidewalls. The sidewalls will typically be slightly resilient and be outwardly diverging adapting the 30 sidewalls to apply force to the shaped portions to maintain the shaped portions in locking engagement with the flange members of the furring channel member. Alternatively, each sidewall may be provided with at least one diverging portion to allow easy attachment of the second ceiling member attachment portion to the furring 6 channel flange members. The slight resilience may also give the second ceiling member attachment portion a snap-fitting action when assembling the attachment system. The second ceiling member attachment portion may alternatively be slideable with respect to the laterally extending flange members. 5 Suitably, the second ceiling member attachment portion will be provided with a substantially centrally positioned tab member on each sidewall. Each tab member will typically be angled slightly inwardly in order to maintain the locking engagement with the flange members of the furring channel. The base wall of the second ceiling member attachment portion may be 10 provided with one or more openings therein to and a pivot member will typically be associated with the opening to allow the respective attachment portions of the mounting clip to pivot or rotate with respect to one another. The pivot member may be an elongate member such as a pin which can be either detachable from the respective attachment portions or permanently fixed 15 thereto. The pivot member may be a short bolt or similar. There may be one or more friction reducing ridges provided on the base wall of the second ceiling member attachment portion between it and the first ceiling member attachment portion to allow for easier rotation or pivoting of the members. The respective attachment portions of the mounting clip are pivotable 20 with respect to one another. Generally, the attachment portions are rotatable in a single plane in substantially 360*. However, it is anticipated by the present inventor that providing mounting clip with at least one spheroidal joint would allow rotation of the attachment members in three dimensions. Brief Description of the Drawings. 25 Various embodiments of the invention will be described with reference to the following drawings, in which: Figure 1 is a perspective view of a mounting clip according to a preferred embodiment of the present invention. Figure 2 is an end view of the mounting clip as illustrated in Figure 1. 30 Figure 3 is a top view of the mounting clip as illustrated in Figure 1. Figure 4 is a bottom view of the mounting clip as illustrated in Figure 1. Figure 5 is a side view of the mounting clip as illustrated in Figure 1.

7 Figure 6 is a side view of a top cross rail attachment portion to suspend the top cross rail from the purlins in a building. Figure 7 is a cross-sectional view of a conventional furring channel. Figure 8 is a cross-sectional view of a conventional top cross rail. 5 Figure 9 is a perspective view of a conventional furring channel. Figure 10 is a perspective view of a conventional furring channel. Figure 11 is a representation of a conventional system for installing a suspended ceiling. Figure 12 is a cross-sectional view of the attachment system and 10 mounting clip in the assembled condition with the top cross rail and furring channel substantially parallel to one another. Figure 13 is a top view of the attachment system illustrated in Figure 12 with the top cross rail and furring channel inclined with respect to one another. Figure 14 is a perspective view of the attachment system illustrated in 15 Figure 13. Detailed Description of the Preferred Embodiment. According to a first preferred aspect of the present invention, a mounting clip 10 is provided. The mounting clip 10 of the first preferred embodiment is illustrated in 20 Figures 1 to 5, and is adapted to allow the secure attachment of a cross rail member as illustrated in Figure 10 to a furring channel 22 as illustrated in Figure 9, whilst allowing the members to rotate with respect to one another as illustrated in Figures 11 to 13. The mounting clip 10 includes a cross rail attachment portion 11. 25 The top cross rail 12 illustrated in Figures 8 and 10 is a substantially U shaped channel member having a base wall 13 and two spaced apart sidewalls 14 extending from the base wall 13. When viewed in cross-section, the sidewalls 14 of the member are provided with a narrower "waist" section 15 located between a wider shoulder portion 16 and a wider "hip" portion 17. The waist portion 15 allows the 30 attachment of a suspension bracket 18 illustrated in Figure 6, which is provided at an end of a wire or cable 19 suspended from a roof member (not shown). The wider shoulder portion 16 carries the weight of the cross rail 12 and the associated ceiling system on the suspension bracket 18.

8 The wider hip portion 17 includes a lateral channel 20 of each side wall 14. Each lateral channel 20 is adapted to receive a correspondingly shaped portion 21 of a mounting clip 10 therein to attach the top cross rail member 12 to the furring channel member 22. 5 The cross rail attachment portion 11 has three shaped portions 21 adapting it for engagement with the lateral channels 20 of the top cross rail 12 as described above. The shaped portions 21 are protuberances which extend from the cross rail attachment portion 11 and are received within the lateral channels 20 of the top cross rail 12. 10 The cross rail attachment portion II has a substantially U-shape with a base wall 23 and a pair of spaced apart sidewalls 24. The sidewalls 24 are slightly resilient and outwardly diverging, adapting the sidewalls 24 to apply force to the shaped portions 21 to maintain the shaped portions 21 in the lateral channels 20 of the top cross rail 12. 15 The cross rail attachment portion 1 1 has a single, substantially centrally position shaped portion 21 on a first sidewall and a pair of spaced apart shaped portions 21 on a second sidewall. The base wall 23 of the cross rail attachment portion 11 has an opening therein to and a pivot member 26 extends through the opening to allow the respective 20 attachment portions of the mounting clip 10 to pivot or rotate with respect to one another. The mounting clip 10 also includes a furring channel attachment portion 27. Each furring channel 22 as illustrated in Figures 7 and 9, is a 25 substantially U-shaped channel member having a base wall 30 and two spaced apart sidewalls 31 extending from the base wall 30. Each of the sidewalls 31 has a free end, provided with a laterally extending flange member 32 used to attach the furring channel 22 relative to a top cross rail 12. The flange members 32 extend outwardly from the respective side walls 3 1. 30 - The furring channel attachment portion 27 has a pair of tab members 28 adapting it for engagement with the laterally extending flange Members 32 of the furring channel 22 as described above. The tab members 28 extend from the furring channel attachment portion 27 and lockingly engage with the flange members 32.

9 The furring channel attachment portion 27 is substantially U-shaped with a base wall 33 and a pair of spaced apart sidewalls 34. Each sidewall 34 is slightly resilient and has an outwardly diverging portion 35 adapting the sidewalls 34 to apply force to the tab members 28 to maintain the tab members 28 in locking 5 engagement with the flange members 32 of the furring channel 22. The furring channel attachment portion 27 is provided with a substantially centrally positioned tab member 28 on each sidewall 34. Each tab member 28 is angled slightly inwardly in order to maintain the locking engagement with the flange members 32 of the furring channel 22. 10 The base wall 33 of the furring channel attachment portion 27 is also provided with an opening therein and the pivot member 26 extends through the opening to allow the respective attachment portions of the mounting clip 10 to pivot or rotate with respect to one another. The pivot member 26 is an elongate member such as a short bolt or 15 similar. There are a pair of friction reducing ridges 37 provided on the base wall 33 of the furring channel attachment portion 27, between it and the cross rail attachment portion 11 to allow for easier rotation or pivoting of the members. According to a second preferred aspect of the present invention, an 20 attachment system for a suspended ceiling is provided. The attachment system is illustrated in Figures I 1 to 13 and includes at least one cross rail member 12 suspended from a roof member (not shown), at least one furring channel member 22 to which one or more ceiling members (not shown) are attachable, and at least one mounting clip 10 for mounting the at least one cross 25 rail member 12 relative to the at least one furring channel 22, the mounting clip 10 including a cross rail attachment portion 11 and a furring channel attachment portion 22 wherein the respective attachment portions of the mounting clip 10 are-pivotable with respect to one another as illustrated in Figures 12 and 13. In the present specification and claims (if any), the word "comprising" 30 and its derivatives including "comprises" and "comprise" include each of the stated integers but does not exclude the inclusion of one or more further integers. Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in 10 connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases "in one embodiment" or "in an embodiment" in various-places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or 5 characteristics may be combined in any suitable manner in one or more combinations. In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention 10 into effect. The invention is, therefore, claimed in any of itsfonrs or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

1. A mounting clip for attaching a first ceiling member having a substantially U-shape relative to a second ceiling member having a substantially U shape in a suspended ceiling system, the mounting clip including: 5 a. An elongate first ceiling member attachment portion to fit within the substantially U-shaped first ceiling member and to extend at least partially along the length of the U-shaped first ceiling member and having engagement portions to engage the first ceiling member; and b. a second ceiling member attachment portion to receive the substantially U 10 shaped second ceiling member, the second ceiling member attachment portion having at least a pair of tab members which extend from the second ceiling member attachment portion and lockingly engage with the second ceiling member; wherein the respective attachment portions of the mounting clip are pivotable with 15 respect to one another.

2. An attachment system for a suspended ceiling including a. at least one first ceiling member suspended from a roof member, b. at least one second ceiling member to which one or more ceiling members are attachable, and 20 at least one mounting clip as claimed in claim 1 for mounting the at least one first ceiling member relative to the at least one second ceiling member.

3. An attachment assembly as claimed in Claim 2 wherein each second ceiling member is a substantially U-shaped channel member having a base wall and two spaced apart sidewalls extending from the base wall. 25

4. An attachment assembly as claimed in Claim 3 wherein each of the sidewalls has a free end, adjacent to which is a laterally extending flange member which may be used to attach the second ceiling member relative to a first ceiling member.

5. An attachment assembly as claimed in any one claims 2 to 4 wherein 30 each first ceiling member is a substantially U-shaped channel member having a base wall and two spaced apart sidewalls extending from the base wall. 12

6. An attachment assembly as claimed in Claim 5 wherein each sidewall is provided with a narrower waist section located between a wider shoulder portion and a wider hip portion including a lateral channel of each side wall.

7. An attachment assembly as claimed in Claim 2 wherein the first ceiling 5 member attachment portion is substantially U-shaped with a base wall and a pair of spaced-apart sidewalls.

8. An attachment assembly as claimed in Claim 7 wherein the first ceiling member attachment portion has shaped portions adapting it for engagement with the sidewalls of the first ceiling member. 10

9. An attachment assembly as claimed in Claim 8 wherein the shaped portions are protuberances which extend from the sidewalls of the first ceiling member attachment portion and the sidewalls of the first ceiling member attachment portion are slightly resilient and outwardly diverging, adapting the sidewalls of the first ceiling member attachment portion to apply force to the shaped portions to 15 maintain the shaped portions relative to the first ceiling member.

10. An attachment assembly as claimed in either Claim 8 or 9 wherein the first ceiling member attachment portion has a single, substantially centrally positioned shaped portion on a first sidewall and a pair of spaced apart shaped portions on a second sidewall. 20

11. An attachment assembly as claimed in any one of Claims 7 to 10 wherein the base wall of the first ceiling member attachment portion is provided with one or more openings therein and a pivot member is associated with the opening to allow the respective attachment portions of the mounting clip to pivot or rotate with respect to one another. 25

12. An attachment assembly as claimed in Claim 2 wherein the second ceiling member attachment portion is substantially U-shaped with a base wall and a pair of spaced-apart sidewalls.

13. An attachment assembly as claimed in Claim 12 wherein the second ceiling member attachment portion has at least one shaped portion adapting it for 30 engagement with the second ceiling member.

14. An attachment assembly as claimed in Claim 13 wherein the shaped portions are tab members which extend from the second ceiling member attachment portion and lockingly engage with the second ceiling member. 13

15. An attachment assembly as claimed in any one of claims 12 to 14 wherein the sidewalls of the second ceiling member attachment portion are slightly resilient and outwardly diverging, adapting the sidewalls of the second ceiling member attachment portion to apply force to the shaped portions to maintain the 5 shaped portions in locking engagement with the second ceiling member.

16. An attachment assembly as claimed in claim 14 wherein the second ceiling member attachment portion is provided with a substantially centrally positioned tab member on each sidewall.

17. An attachment assembly as claimed in any one of claims 12 to 16 10 wherein the base wall of the second ceiling member attachment portion is provided with one or more openings therein and a pivot member is associated with the opening to allow the respective attachment portions of the mounting clip to pivot or rotate with respect to one another.

18. An attachment assembly as claimed in any one of claims 11 to 17 15 wherein the pivot member is an elongate member.

19. An attachment assembly as claimed in any one of claims 2 to 18 wherein the respective attachment portions of the mounting clip are pivotable with respect to one another in a single plane in substantially 360'.

20. A mounting clip substantially as described herein with reference to 20 Figures 1 to 5.

21. An attachment system substantially as described herein with reference to Figures 12 to 14.