Channel support member, method for making channel support member and support system for a drywall ceiling

Abstract

 Channel support member (2) for use in a support system (1) for drywall ceilings comprising:
- a longitudinal extending base portion (3),
- a first leg portion (4) extending in an upward direction along a first longitudinal edge (6) of the base portion (3),
- a second leg portion (5) extending in an upward direction along a second longitudinal edge (7) of the base portion (3) opposing the first longitudinal edge (6) of the base portion (3),
- the first and the second leg portion (4, 5) respectively comprising first and second fastening means (8, 9) provided to engage corresponding respective first and second openings (10, 11) in a runner (22) of the support system (1),
the first and second fastening means (8, 9) being separated from each other by a first distance (12) measured along width direction of the channel member (2), wherein at least a respective first and second part (18, 19) of the second and first leg portion (4, 5) extend towards each other from the respective first and second longitudinal edge (6, 7) such that the first and second longitudinal edge (6, 7) are separated from each other by a second distance (13) measured along the width direction of the channel member (2), the first distance (12) being smaller than the second distance (13).

Description

[0001] The present invention relates to a channel support member, according to the preamble of the first claim.

[0002] The present invention also relates to a method for making such a channel support member and a support system for a drywall ceiling.

[0003] Channel support members for use in a support system for drywall ceilings have already been described by US 4,208,851. The channel support members comprise a longitudinally extending base portion. The base portion is provided to receive screws such that drywall can be screwed to the base portion. The channel support member according to US 4,208,851 further comprises a first leg portion extending in an upward direction along a first longitudinal edge of the base portion and a second leg portion extending in an upward direction along a second longitudinal edge of the base portion opposing the first longitudinal edge of the base portion. The first and second leg portion described by US 4,208,851 are resiliently biased away from each other. The first and the second leg portion respectively comprise first and second fastening means provided to engage corresponding respective first and second openings in a runner of the support system. The first and the second fastening means are separated from each other by a first distance measured along width direction of the channel member.

[0004] However, attachment of the drywall to the channel support members is limited to the base portion of the channel support member. It has been found that the width of the base portion of the channel support member is relatively limited and that, consequently, it is difficult to screw into the base portion to attach the drywall to the channel support member.

[0005] There is thus a need for a channel support member for which it is easier to attach a drywall to the channel support member.

[0006] This is achieved according to the present invention with a channel support member according to the characterising part of the first claim.

[0007] Thereto, at least a respective first and second part of the second and first leg portion extend towards each other from the respective first and second longitudinal edge such that the first and second longitudinal edge are separated from each other by a second distance measured along the width direction of the channel member, the first distance being smaller than the second distance.

[0008] An analyses of the problem has shown that the ease with which the drywall can be attached to the channel support member is related to the width of the base portion, a larger width providing a larger area to which the drywall can be screwed. The inventor has found that with a channel support member according to the invention the width, the second distance, of base portion of the channel support member can be increased without having to increase the first distance. The ease with which the drywall can be attached to the channel support member can therefore be increased while allowing the channel support member to be used without having to adapt the corresponding first and second openings in the runners of the support system. The channel support member according to the invention can therefore be used in known systems for drywall ceilings while offering the advantage of an easier attachment of the drywall to the support system.

[0009] A further advantage of the channel support member and the support system is that construction of the support system for a drywall ceiling can be performed before application of the drywall plates to the support system to finalise the drywall ceiling such that the construction of the support system can be performed substantially independently from the application of the drywall plates. Such a construction system allows that some constructional steps, such as mounting building constructions into the support systems such as light armatures, etc., are taken after the support system has been constructed but before the drywall plates have been applied, which is less cumbersome.

[0010] The inventor has found that the presence of the two fastening means allows an improved fastening of the channel support member in the runner since rotation along longitudinal axis of the channel support member and/or rotation along a rotational axis substantially perpendicular to the longitudinal axis of the channel support member is prevented.

[0011] In preferred embodiments of the channel support member according to the invention a respective third and/or fourth part of the first and/or second leg portion adjacent to the respective first and/or second longitudinal edge extends in a direction substantially perpendicular to or away from the base portion. The third and/or fourth parts of the leg portions allow that additional room is created between the leg portion and the base portion for receiving for example screws so that drywall can be more easily be attached to the support system.

[0012] In preferred embodiments of the channel support members according to the invention, a supporting part of a longitudinal end part of the base portion is provided to be at least partly supported by a supporting flange of the runner of the support system when the fastening means engage the corresponding first and second opening in the runner of the support system and in that the supporting part is elevated in upward direction over a distance substantially corresponding with the thickness of the supporting flange of the runner. Such an elevation allows that after mounting of the channel support member to the runner, a more gradual transition from the supporting flange to the channel support member is obtained. Such a more gradual transition allows a better attachment of drywall to the assembly of the channel support member and the runner of the support system for drywall ceilings. Preferably, the undersides of the base portion and the runner are as a result substantially coplanar resulting in an improved attachment of drywall plates. Moreover, undesired tensions in drywall plates mounted to the support system, due to uneven undersides of the base portion of the channel support member and the runner are prevented.

[0013] In preferred embodiments of the channel support member according to the invention, the base portion comprises a cut at a longitudinal end part of the base portion extending at least partially in longitudinal direction. By providing such a cut, the inventor has found that the first and second leg portion can be bent more easily towards each other allowing the first and the second fastening means to be more easily moved through the first and second openings provided in the runner.

[0014] The invention also relates to a method for making a channel support member comprising the steps of folding a first and second side part comprising fastening means provided to engage corresponding respective first and second openings in a runner of the support system after making of the channel support member, of a longitudinal metal sheet in an upward direction along a respective first and second longitudinal folding line for forming the base portion delimited by the first and second longitudinal edge until the first and the second side part extend in a direction substantially perpendicular to or away from the base portion, creating a supporting part elevated in upward direction after which at least part of the first and the second side part are folded in a direction towards each other such that a first distance between fastening means measured along width direction of the channel member becomes smaller than a second distance between the first and the second longitudinal edges measured along the width direction of the channel member.

[0015] The inventor has found that such a construction of the channel support member allows for an easy construction of the supporting part.

[0016] The invention also relates to a support system for a drywall ceiling comprising a channel support member according to the invention.

[0017] Other details and advantages of the device according to the invention will become apparent from the enclosed figures and description of preferred embodiments of the invention.

[0018] Figure 1a shows a cross-sectional view of a preferred embodiment of the channel support member according to the current invention.

[0019] Figure 1b shows a longitudinal view of the channel support member of figure 1 a.

[0020] Figure 1c shows a top view of the channel support member of figure 1 a.

[0021] Figure 1d shows a detail of an end part of the channel support member according to figure 1c in a view in perspective.

[0022] Figure 2 shows the channel support member according to figures 1a - 1d engaging a runner in perspective.

[0023] Figure 3 shows a runner engaged by two channel support members according to the invention.

[0024] Figure 4 shows a view from below of a drywall ceiling comprising channel support members according to the invention.

[0025] Figure 5 shows a view from above of the drywall ceiling according to figure 4.

[0026] Figures 1a - 1c show a channel support member 2 according to the invention. The channel support member 2 is provided to be used in a support system 1 for drywall ceilings as for example shown in figures 4 and 5. The support system 1 comprises channel support members 2 and runners 22 which are interconnected to form a web as for example shown in figure 5.

[0027] The channel support member 2 comprises a longitudinal extending base portion 3 being delimited by a first 6 and a second 7 longitudinal edge, the first longitudinal edge 6 opposing the second longitudinal edge 7, and extending from a first longitudinal end part 17 to a second longitudinal end part. A first 4 and second 5 leg portion extends from respectively the first 6 and second 7 longitudinal edge in an upward direction. The first and second leg portion 4, 5 respectively comprise first 8 and second 9 fastening means which are provided to engage corresponding respective first 10 and second 11 openings in a runner 22 of the support system 1. The first 8 and second 9 fastening means are separated from each other by a first distance 12 measured along width direction of the channel support member 2. At least a first and second part 18, 19 of the second 5 and first 4 leg portion extend towards each other from the respective first 6 and second 7 longitudinal edge such that the first 6 and second 7 longitudinal edge are separated from each other by a second distance 13 measured along the width direction of the channel member 2. The first distance 12 is smaller than the second distance 13.

[0028] The channel support member 2 preferably is made from metal, such as for example steel, stainless steel, aluminium, etc. However, the channel support member 2 can also be made from other materials such as for example plastic, wood, etc.

[0029] The channel support member 2 shown in figures 1a - 1c is formed as a unitary piece. However, this is not critical for the invention and the different parts of the channel support member 2 can also be made from different pieces which are interconnected, for example by gluing, stapling, riveting, nailing, screwing, welding, soldering, etc. such as to form the channel support member 2.

[0030] The channel support member 2 shown in figures 1a - 1c has a longitudinal shape, although this is not critical for the invention and the channel support member 2 according to the invention can also have any other shape deemed appropriate by the person skilled in the art.

[0031] The dimensions of the channel support member 2 preferably are adapted to the specific use of the channel support member 2 in the support system 1 for drywall ceilings and the length of the base portion 3 preferably is of the same order of magnitude as readily available drywall plates, also known as drywall boards, as shown in figures 4 and 5.

[0032] The width of the base portion 3 preferably is wider than the width of known channel support members, so that drywall plates can be more easily mounted to the channel support member 2 according to the invention.

[0033] The base portion 3 shown in figure 1a - 1c preferably is rectangular, but can have any form deemed appropriate by the person skilled in the art. The base portion 3, more in particular the underside which will face the drywall plates when they are mounted to it, preferably is provided to be adjacent to drywall plates mounted to it, as shown in figures 4 and 5. The base portion 3 thereto preferably is substantially flat, although, for example when using non-flat drywall plates, other shapes are possible.

[0034] The underside of the base portion 3 preferably is provided to be attached to drywall plates. The drywall plates can be attached in any way known to the person skilled in the art such as for example by nailing, screwing, riveting, gluing, etc. Preferably, the drywall plates are attached to the base portion 3 by screwing. The underside of the base portion 3 thereto preferably is provided with a knurled surface such that the screws can be more easily positioned with respect to the base portion 3 after being pierced through the thickness of the drywall plate. The underside of the base portion can however also be more or less flat.

[0035] As shown in figure 1b a supporting part 16 of a longitudinal end part 17 of the base portion 3 is provided to be at least partly supported by a supporting flange 23 of the runner 22 of the support system 1 when the fastening means 8, 9 engage the corresponding first and second opening 10, 11 in the runner 22 of the support system. The supporting part 16 supported by a runner 22 is for example shown in more detail in figure 2.

[0036] The supporting part 16 preferably is elevated in upward direction, i.e. away from the upper side of the base portion 3, over a distance substantially corresponding with the thickness of the supporting flange 23 of the runner 22. This is however not critical for the invention and the supporting flange 23 may also be substantially in the plane of the underside base portion 3.

[0037] The base portion 3 preferably comprises a cut 37 at a longitudinal end part, for the example the first longitudinal end part 17 of the base portion 3 preferably one at each of the two longitudinal end parts as shown in figure 1c, extending at least partially in longitudinal direction. The cut 37 has been found to increase the resiliency with which the first and second leg portion 18, 19 are biased towards each other.

[0038] Preferably, the base portion 3 is provided with at least one crease 26, 27, 28 extending along longitudinal direction of the base portion 3 of the channel support member 2. The crease 26, 27 and 28 preferably provide the person installing the drywall plates to the channel support member 2 with useful information for installing the drywall plate. Preferably, a first crease 27 indicates the centre of the base portion 3 such that the person installing the drywall plates can install the drywall plate more precisely. Preferably, a second crease 26 indicates a position from where a drywall plate, when positioned adjacently to the centre of the base portion, preferably by using the first crease 27, is additionally provided with reinforcing means to allow a better fastening through, for example, screws. The second crease 26 therefore indicates to the person installing the drywall plate where preferably screws are driven through the plate. Preferably, a third crease 28 is provided such that also for a second drywall plate, positioned adjacently to a first drywall plate and mutually adjacently to the centre of the base portion 3, the region where the second drywall plate is provided to be preferably screwed. Most preferably, but not critical for the invention, the first, second and third crease 27, 26, 28 are all provided on the base portion 3 to improve the ease of mounting of drywall plates to the channel support member 2. Preferably, the second 26 and/or third crease 28 are provided at substantially the centre between the first crease 27 and the first 6 and second 7 edge respectively.

[0039] Preferably, the base portion 3 comprises an indication of the longitudinal centre of the base portion 3 which allows an improved ease of installing the drywall plates to the base portion 3. More preferably, the centre is indicated by an opening 38. The opening 38, in addition to marking the longitudinal centre of the base portion 3, also can be used for mechanically transporting the base portion 3, for example while making the channel support member 2. The opening 38 is however not critical for the invention and the longitudinal centre can also be indicated by for example a local elevation, a local decrease, a folding line, etc.

[0040] The first 4 and second 5 leg portion preferably are symmetrical with respect to each other, however this is not critical for the invention and the first 4 and second 5 leg portion can also be asymmetric, as deemed appropriate by the person skilled in the art.

[0041] The first 4 and second 5 leg portion preferably are connected to the base portion 3 by respectively a first 24 and a second 25 folding line, as shown in figure 1a.

[0042] The first 18 and second 19 part, which extend towards each other, preferably extend towards each other under a respective first and second angle 14, 15 with the base portion 3 which are substantially identical to each other, as shown in figure 1a. This is however not critical for the invention and the first and second angle 14, 15 can be substantially different from each other, as long as the first distance 12 is smaller than the second distance 13. The first angle 14 can for example be substantially 90° whereas the second angle 15 is smaller than 90°.

[0043] Preferably, the first and second angle 14, 15 are substantially identical and are between 0° - 85°, preferably an angle of between 20° - 70°, more preferably an angle of between 30° - 60°, even more preferably 40° - 50° and most preferably an angle of between 43° - 47°, such as for example 45°.

[0044] Preferably, the first 18 and second part 19 of the first and second leg portion 4, 5 are provided at a top part, i.e. a part remote from the base portion 3, of the leg portions 4, 5 and are resiliently biased towards each other.

[0045] Although not shown, the part 18, 19 of the first 4 and second 5 leg portion extending towards each other may be respectively and directly connected to the first longitudinal edge 6 and the second longitudinal edge 7 of the base portion 3. However, preferably, the first and second leg portion 18, 19 comprise a third 29 and fourth 30 part respectively extending between respectively the first and second longitudinal edge 6, 7 and the first and second part 18, 19. Preferably, the third and fourth part 29, 30 extend substantially away from the base portion 3 and more preferably extend along a direction substantially perpendicular to the base portion 3, as shown in figure 1a. The height of the third 29 and fourth 30 part preferably is determined in function of the first 12 and second 13 distance and the first and second angle 14, 15 and the first 10 and second 11 opening in the runner 22.

[0046] Preferably, the third 29 and fourth 30 part are connected to the base portion 3 by respectively the first 24 and the second 25 folding line. Preferably, the first 18 and second 19 part are connected to respectively the third 29 and fourth 30 part by a third 31 and fourth 32 folding line, as shown in figure 1 a.

[0047] Preferably, the first 4 and second 5 leg portion comprise a fifth 33 and a sixth 34 part extending away from each other from the first 18 and the second 19 part along a direction which is preferably but not necessarily substantially parallel to the base portion 3. The extending direction of the fifth 33 and the sixth part 34 preferably are adapted to the first 10 and second 11 openings in the runner 22 of the support system 1. The fifth 33 and sixth 34 part are connected to respectively the first 18 and the second 19 part with a fifth 35 and sixth 36 connecting line, more preferably fifth 34 and sixth 35 folding line. Preferably, longitudinal sides of the fifth 32 and sixth 33 part opposing the fifth 35 and sixth 36 connecting line are delimited by hemmed edge.

[0048] The first and second fastening means 8, 9 are provided at the longitudinal end part 17 of the channel support member 2 and extend from the first and second leg portion 4, 5 along longitudinal direction of the channel support member 2. Preferably, the first and second fastening means 4, 5 are provided to engage standard first and second openings 10, 11 of a runner 22 and more preferably the first distance 12 between the first and second fastening means 8, 9 is thereto provided. The first and second leg portion 4, 5 are provided to be bent towards each other so that the fastening means 8, 9 can be pushed together and moved through the first and second openings 10, 11 of the runner 22. After releasing the first and second fastening means 8, 9, the first and second fastening means 8, 9, again move away from each other and can now engage the openings 10, 11 of the runner 22. Preferably, the fastening means 8, 9 are thereto provided with slits 20, 21 which are provided to engage a side of the openings 10, 11 of the runner 22. As shown in figure 1c, the fastening means 8, 9 are preferably provided at both end parts of the channel support member 2 are provided with fastening means 8, 9.

[0049] The method for making the channel support member comprises the steps of folding a first and second side part, comprising fastening means 8, 9 provided to engage corresponding respective first and second openings 10, 11 in a runner 22 of the support system 1 after making of the channel support member 2 of a longitudinal metal sheet in an upward direction along a respective first and second longitudinal folding line 24, 25 for forming the base portion 3 until the first and the second side part extend in a direction substantially perpendicular to or away from the base portion 3. Subsequently, the supporting part 16 is elevated in upward direction after which at least part of the first and the second side part are further folded in a direction towards each other such that the first distance 12 between the fastening means 8, 9 measured along width direction of the channel member 2 becomes smaller than the second distance 13 between the first and the second longitudinal edges 6, 7 formed by the first and second folding lines 24, 25 measured along the width direction of the channel member 2.

Claims

1. Channel support member (2) for use in a support system

(1) for drywall ceilings comprising:

- a longitudinal extending base portion (3),

- a first leg portion (4) extending in an upward direction along a first longitudinal edge (6) of the base portion (3),

- a second leg portion (5) extending in an upward direction along a second longitudinal edge (7) of the base portion (3) opposing the first longitudinal edge (6) of the base portion (3),

- the first and the second leg portion (4, 5) respectively comprising first and second fastening means (8, 9) provided to engage corresponding respective first and second openings (10, 11) in a runner (22) of the support system (1),

- the first and second fastening means (8, 9) being separated from each other by a first distance (12) measured along width direction of the channel member (2),

characterized in that at least a respective first and second part (18, 19) of the second and first leg portion (4, 5) extend towards each other from the respective first and second longitudinal edge (6, 7) such that the first and second longitudinal edge (6, 7) are separated from each other by a second distance (13) measured along the width direction of the channel member (2), the first distance (12) being smaller than the second distance (13).

2. Channel support member as claimed in claim 1,
characterized in that a respective third (29) and/or fourth (30) part of the first and/or second leg portion (4, 5) adjacent to the respective first and/or second longitudinal edge (6, 7) extends in a direction substantially perpendicular to or away from the base portion (3).

3. Channel support member as claimed in any one of the preceding claims, characterized in that a supporting part (16) of a longitudinal end part (17) of the base portion (3) is provided to be at least partly supported by a supporting flange (23) of the runner (22) of the support system (1) when the fastening means (8, 9) engage the corresponding first and second opening (10, 11) in the runner (22) of the support system (1) and in that the supporting part (16) is elevated in upward direction over a distance substantially corresponding with the thickness of the supporting flange (23) of the runner (22).

4. Channel support member as claimed in any one of the preceding claims, characterized in that the first and second part (18, 19) extend towards each other under an angle of between 0° - 85°, preferably an angle of between 20° - 70°, more preferably an angle of between 30° - 60°, even more preferably 40° - 50° and most preferably an angle of between 43° - 47°, such as for example 45°.

5. Channel support member as claimed in any one of the preceding claims, characterised in that the base portion (3) comprises a cut (37) at a longitudinal end part (17) of the base portion (3) extending at least partially in longitudinal direction.

6. Method for making a channel support member (2) as claimed in any one of claims 3 - 5, comprising the steps of folding a first and second side part comprising fastening means (8, 9) provided to engage corresponding respective first and second openings (10, 11) in a runner (22) of the support system (1) after making of the channel support member (2), of a longitudinal metal sheet in an upward direction along a respective first and second longitudinal folding line (24, 25) for forming the base portion (3) delimited by the first and second longitudinal edge (6, 7) until the first and the second side part extend in a direction substantially perpendicular to or away from the base portion (3), creating a supporting part (16) elevated in upward direction after which at least part of the first and the second side part are folded in a direction towards each other such that a first distance (12) between fastening means (8, 9) measured along width direction of the channel member (2) becomes smaller than a second distance (13) between the first and the second longitudinal edges (6, 7) measured along the width direction of the channel member (2).

7. Support system for a drywall ceiling comprising a channel support member (2) as claimed in any on of claims 1 - 5.

Drawing