Grid tee for suspension ceilings or the like

Abstract

A structure of a grid tee member for suspension ceilings, and a method for producing such structure is disclosed. Such grid tee provides a web, a bulb at one web extremity and a flange at the other web extremity. The tee section includes three strips of material in which the first strip is relatively thin and is shaped to provide the web, a portion of the bulb and a portion of the flanges. A separate cap strip is secured to the flanges on the side thereof remote from the web and separate stiffening material having a generally U-shaped cross section is located within the bulb with the base of the U located at the extremity of the section. The three strips provide a structure in which material is concentrated at the extremities and is therefore efficiently placed to provide a high moment of inertia and high rigidity to the total structure. The thickness of the three strips is separately selected so that the material forming the section efficiently functions to provide a cross section in which the centroid is substantially midway between the extremities. The illustrated structure is produced by a method in which the stiffener strip and the strip forming the main structure of the section are lance knitted while the two strips are in the flat condition and then are simultaneously formed to produce the bulb with a U-shaped stiffener enclosed within the bulb.

What is claimed is: 
     
       1. An elongated grid tee for suspension ceilings or the like having a web, a bulb, and oppositely extending flanges comprising a first elongated strip of thin metal bent along its center to provide a closed bulb and extending from said bulb in face-to-face abutting adjacency to provide a central web having two abutting layers and at the edge of said web remote from said bulb bent to provide oppositely extending flanges, a cap formed of a separate second strip of thin metal secured to and extending along substantially the entire length of said flanges on the side thereof remote from said bulb, and a stiffener formed of a separate third strip of metal enclosed within said bulb, a substantial portion of said stiffener engaging the surface of said bulb so that said stiffener and the material of said bulb cooperate to provide a substantially unitary structure, said stiffener and cap increasing the material at the extremities of said tee without increasing the thickness of said web. 
     
     
       2. An elongated grid tee as set forth in claim 1, wherein said third strip of metal is substantially thicker than said first strip of metal, and the centroid of the tee is substantially midway between its extremities. 
     
     
       3. An elongated grid tee as set forth in claim 2, wherein said stiffener is positioned with a substantial portion thereof substantially adjacent to the bulb extremity of said tee. 
     
     
       4. An elongated grid tee as set forth in claim 3, wherein said cap is bent around the opposite edges of said flanges to secure said cap and to provide additional material at the flange extremity of said tee. 
     
     
       5. An elongated grid tee as set forth in claim 3, wherein said cap is provided with a double reverse bend along the edges of said flanges and said flanges are provided with a single reverse bend to connect said cap to said flanges and provide an edge bead having five layers of material. 
     
     
       6. An elongated grid tee as set forth in claim 5, wherein said first strip is provided with a longitudinal rib extending lengthwise of said flanges inwardly from said bead to provide additional stiffness and additional material adjacent to the web extremity of said tee. 
     
     
       7. An elongated grid tee as set forth in claim 3, wherein said stiffener is generally U-shaped in cross section with the base thereof located along the extremity of said tee. 
     
     
       8. An elongated grid tee as set forth in claim 7, wherein said stiffener and said first strip are secured together at intervals along their length. 
     
     
       9. An elongated grid tee as set forth in claim 7, wherein said stiffener is formed with an inwardly directed pleat substantially at the center of the base thereof. 
     
     
       10. An elongated grid tee as set forth in claim 9, wherein said first elongated strip bridges across said pleat. 
     
     
       11. An elongated grid tee as set forth in claim 7, wherein said first strip and said stiffener are lance stitched together at intervals along their length to connect them together and to provide lateral openings through said bulb to receive hanger means. 
     
     
       12. An elongated grid tee as set forth in claim 11, wherein said first strip is formed of embossed metal to increase its rigidity. 
     
     
       13. An elongated grid tee as set forth in claim 11, wherein said second strip is coated with a finish material and provides a finished exposed surface of said tee when said tee is installed in a ceiling system. 
     
     
       14. An elongated grid tee as set forth in claim 13, wherein said tee is provided with end connectors for connecting said tee to other tees and to form therewith a grid, and said end connectors are formed of separate pieces secured to the ends of said tee. 
     
     
       15. An elongated grid tee for suspension ceilings or the like having a web extending along a central plane, a bulb at one extremity of said web and a flange at the opposite extremity of said web and which is substantially symmetrical with respect to said central plane, comprising an elongated first strip of thin metal bent to form said web providing two layers of abutting material, a portion of said flange and a portion of said bulb; a cap formed of a second strip of thin metal engaging and secured to said portion of said flange on the side thereof opposite said web along substantially the entire length thereof; and a third strip of metal having a thickness substantially greater than the thickness of said first and second strips secured to said portion of said bulb along substantially the entire length thereof, a substantial portion of said third strip engaging the surface of said portion of said bulb so that they cooperate to provide a substantially unitary structure, said second and third strips providing additional material on said tee so that the effective thickness of said web and said bulb are increased to concentrate material at the extremity of said tee without increasing the thickness of said web and so that the centroid of the moment of inertia of said tee is substantially midway between said extremities. 
     
     
       16. An elongated grid tee as set forth in claim 15, wherein said cap is provided with a reverse bend around the opposite edges of said flange portion of said first strip to secure said cap and to provide additional stiffness at the flange extremity of said tee. 
     
     
       17. An elongated grid tee as set forth in claim 15, wherein said first strip has a thickness substantially no greater than about 0.0061 inches, said second strip has a thickness substantially no greater than about 0.0072 inches, and said third strip has a thickness within the range of about 0.012 inches and 0.030 inches. 
     
     
       18. An elongated grid tee as set forth in claim 17, wherein said first strip is embossed to increase its rigidity, and end connectors are provided at each end of said tee, said end connectors being formed as separate pieces connected to said tee. 
     
     
       19. An elongated grid tee as set forth in claim 15, wherein said cap is formed with a double reverse bend along the opposite edges of said flange portions to provide three layers of cap material at the flange extremity of said tee. 
     
     
       20. An elongated grid tee as set forth in claim 19, wherein the opposite edges of said flange portions of said first strip are formed with a reverse bend to provide two layers of first strip material at the flange extremity at said tee. 
     
     
       21. An elongated grid tee as set forth in claim 20, wherein said bulb encloses said third strip, and said third strip is connected to said first strip along its length. 
     
     
       22. An elongated grid tee as set forth in claim 21, wherein said third strip is a U-shaped channel with a base of said U located at an extremity of said tee. 
     
     
       23. An elongated grid tee as set forth in claim 22, wherein said third strip is formed with an accordion pleat along the extremity of said bulb. 
     
     
       24. An elongated grid tee having a web, a bulb, and oppositely extending flanges for use in suspended ceilings or the like and which is symmetrical about a central plane comprising a first elongated strip of thin metal, said first strip extending laterally inward from one edge thereof to a first substantially right angle bend located substantially at said central plane to provide a first flange portion, extending from said first right angle bend along said plane to provide a first web portion, providing a reverse bend at the end of said first web portion to provide a portion of said bulb, extending from said reversed bend back substantially along said central plane in abutting engagement with said first flange portion to a second right angle bend to provide the remaining portion of said web, and extending laterally from said second right angle bend to its opposite edge to provide a second web portion, a cap formed of a separate elongated second strip of thin metal engaging substantially the entire length of said first and second flange portions on the side thereof remote from said web connected at its edges to said first elongated strip at the edges thereof, and a third elongated strip of metal engaging and secured to said first strip at said bulb along substantially the entire length thereof, said second and third strip cooperating to concentrate the material of said tee at the extremities of said web without increasing the thickness of said web and cooperating to provide said tee with a moment of inertia having a centroid located substantially midway between the extremities of said tee. 
     
     
       25. An elongated grid tee as set forth in claim 24, wherein said cap is formed with double reverse bends along its edges, and said first strip is provided with reverse bends along its edges so that at least five layers of material are provided at the edges of said flanges. 
     
     
       26. An elongated grid tee as set forth in claim 24, wherein said first strip is formed with a longitudinal rib substantially adjacent to the edge of each of said flanges. .Iadd. 
     
     
       27.  A grid tee for suspension ceilings or the like having a central web, a bulb along one side of said web, and oppositely extending panel-supporting flanges along the opposite side of said web, comprising an elongated strip of metal bent substantially along its center to form a closed bulb, said strip of metal extending in face-to-face adjacency to form a double layer central web extending from said bulb, said strip of metal being bent to extend laterally in opposite directions to form panel-supporting flanges along the side of said web remote from said bulb, said bulb providing at least two laterally extending layers of metal along the extremity of said bulb remote from said web to increase the load-carrying capacity of said tee, a substantial portion of said two laterally extending layers engaging each other, said two laterally extending layers being sufficiently interconnected along their length so that they cooperate to provide a substantially unitary structure along the extremity of said bulb and extending along substantially the entire length of said tee, said two laterally extending layers co-acting as a unitary structure to resist deflection of said grid tee..Iaddend. .Iadd.28. A grid tee as set forth in claim 27, wherein one of said two laterally extending layers is provided by said elongated strip of metal and the other of said two laterally extending layers is provided by a separate strip secured to said elongated strip..Iaddend. .Iadd.29. A grid tee as set forth in claim 28, wherein said separate strip is enclosed within said bulb. .Iaddend. .Iadd.30. A grid tee as set forth in claim 29, wherein said separate strip is U-shaped..Iaddend. .Iadd.31. A grid tee as set forth in claim 28, wherein 
     
     
        said separate strip is U-shaped..Iaddend. .Iadd.32.  A grid tee for suspension ceilings or the like, comprising a first strip of metal bent to provide a hollow, closed bulb, said first strip providing a central web extending from said bulb and oppositely extending panel-supporting flanges along the side of said web remote from said bulb, and a separate strip of metal secured to said bulb of said first strip providing a separate metal layer substantially adjacent to the extremity of said tee to increase the load-carrying capacity thereof, said separate metal layer of said second strip being in face-to-face abutting contact with the adjacent metal of said bulb along said extremity of said tee and extending the length of said tee, said two abutting layers of metal being sufficiently connected along the length of said tee so that they cooperate to provide a substantially unitary structure along the length of said tee resisting the deflection of said tee..Iaddend. .Iadd.33. A grid tee as set forth in claim 32, wherein said second strip of metal is enclosed by said first strip..Iaddend. .Iadd.34. A grid tee as set forth in claim 33, wherein said strips are lance-stitched together along their length..Iaddend. .Iadd.35. A grid tee as set forth in claim 32, wherein a cap formed of a third separate strip is secured to said flanges to provide multilayer flanges..Iaddend. .Iadd.36. A grid tee as set forth in claim 32, wherein said first strip provides a web including two layers in face-to-face 
     
     
        abutting contact..Iaddend. .Iadd.37.  A grid tee as set forth in claim 32, wherein said second strip is an inverted U-shape providing a laterally extending metal layer substantially adjacent to the extremity of said tee and two legs extending in a direction toward said web, and said legs are lance stitched to the metal of said bulb..Iaddend. .Iadd.38. A grid tee for suspension ceilings or the like having a central web, a bulb along one side of said web, and oppositely extending panel-supporting flanges along the opposite side of said web, comprising an elongated strip of metal bent substantially along its length to form a bulb, said strip of metal extending from said bulb to form a central web extending from said bulb, said strip of metal being bent to extend laterally in opposite directions to form panel-supporting flanges along the side of said web remote from said bulb, said bulb providing at least two laterally extending layers of metal along the extremity of said bulb remote from said web to increase the load-carrying capacity of said tee..Iaddend.