Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
  • E04B9/0428—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like having a closed frame around the periphery
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/06—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
  • E04B2009/0492—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like with fabrics tensioned on frames

Definitions

• the present invention generally relates to suspended ceilings having a plurality of ceiling tiles supported by a structural grid and, more specifically, to an improved suspended ceiling system incorporating improved ceiling tiles that may be more easily adapted for fitting around other structures and obstructions during the installation of a suspended ceiling.
• suspended ceilings are spaced from a primary overhead structure such as ceiling joists or the underside of a reinforced concrete structure for establishing a substantially level and more aesthetically pleasing ceiling for a finished space.
• Suspended ceiling provide improved flexibility for finishing a space over ceiling systems that are mounted directly to the primary overhead structure or furring strips or other attachment regions provided on the primary overhead structure.
• Suspended ceilings generally comprise a plurality of individual ceiling tiles with the individual tiles typically having a rectangular or square shape.
• the composition of the individual ceiling tiles utilized in such systems have also been manufactured from many different materials such as pressed fibrous materials or synthetic polymers and synthetic resins that may be cast to form the tile body.
• the ceiling tiles may also be produced with at least one embossed or textured surface for improving the aesthetic appearance and/or improved sound absorption.
• An alternative type of ceiling tiles may be manufactured using a combination of a frame and a cover layer provided on and supported by the frame.
• FIGS. 1, 2 A and 2B One conventional construction of a ceiling tile incorporating a frame and a cover layer is illustrated in FIGS. 1, 2 A and 2B.
• Conventional suspending ceiling systems typically use a track system or grid assembly for supporting the individual tiles. It will be appreciated that proper installation of the ceiling tiles, the grid assembly and tiles will typically be configured to within a relatively narrow range of geometrical requirements.
• a conventional assembly will be configured so that the exposed faces of the ceiling tiles generally lie in a single plane and will be arranged in orderly arrays of rows and columns with some configurations providing for alternating rows or columns that may be offset from the adjacent columns by a predetermined uniform distance.
• the ceiling tiles are generally arranged such that a uniform pattern is created.
• suspending ceiling systems must provide one or more methods for adapting the grid assembly and the ceiling tiles to accommodate obstructions or other alterations in the profile of the ceiling space at, for example, corners, pipes, ducts, pillars and the like, as well as around the perimeter of the ceiling space.
• a wall angle molding is attached around the inside perimeter of the walls at the height determined for the grid assembly.
• the grid assembly is then constructed using inverted "T-shaped" elements that are aligned with and attached to the wall angle molding.
• the grid elements are fabricated of metal and must be cut with tin snips, nibblers, metal saws or other suitable cutting instruments with any residual burrs and sharp edges being filed off before installation.
• the basic ceiling tiles include a peripheral frame surrounding a single primary opening with the peripheral frame configured to provide a main portion providing a support surface and an offset portion providing an offset surface.
• a cover layer such as a woven or non-woven fabric or a scrim may be stretched across the opening and attached to the frame with the support surface generally defining the plane of the portion of the cover layer that extends over the opening.
• a peripheral recess will be formed between the cover layer and the offset surface of the frame.
• the ceiling tile may then be customized or adapted using one or more premanufactured trim pieces that include end portions configured for insertion into the peripheral recess and an intermediate portion that can be attached to and provide support for an underlying portion of the cover layer.
• trim piece Once the trim piece is in place, a portion of the peripheral frame and the cover layer can be removed, typically by cutting, to complete the customized ceiling tile which incorporates the trim piece as a portion of the modified tile periphery.
• the trim pieces may be provided in a range of standard configurations including straight, curved or angled configurations so that the ceiling tiles can be easily adapted by installers to accommodate a wide range of obstructions such as pipes, columns, that may interrupt the profile of the suspended ceiling.
• the peripheral frame utilized in the ceiling tiles may be provided in a wide range of configurations.
• the peripheral frame may include an extended portion for concealing at least a portion of the lower surface of the supporting grid and reducing the apparent spacing between adjacent ceiling tiles.
• the peripheral frame may also incorporate one or more of a variety of releasable retaining structures or elements that provide temporary attachment of the ceiling tile to the supporting grid.
• FIG. 1 is a plan view of a conventional ceiling tile construction
• FIGS. 2 A and 2B are cross-sectional views of conventional ceiling tile construction taken along line A-A' of FIG. 1;
• FIGS. 3 A and 3B are a plan view and cross-sectional view along line A-A' of an exemplary ceiling tile construction according to the present invention
• FIGS. 4A and 4B are a plan view and cross-sectional view along line A-A' of an exemplary ceiling tile construction generally corresponding to FIGS. 3 A and 3B to which a trim piece has been added;
• FIGS. 5 A and 5B are a plan view and cross-sectional view along line A-A' of an exemplary ceiling tile construction generally corresponding to FIGS. 4 A and 4B on which a portion of the original tile has been removed to prepare a customized ceiling tile;
• FIGS. 6 A and 6B are plan views of other exemplary customized ceiling tile configurations in which a portion of the original tile has been removed to prepare a customized ceiling tile;
• FIGS. 7 A and 7B are cross-sectional views of other exemplary ceiling tile configurations illustrating exemplary configurations for supporting the ceiling tiles from a supporting frame or grid;
• FIGS. 8A-8F are cross-sectional views of other exemplary ceiling tile configurations; and FIGS. 9A-9C are cross-sectional views of other exemplary ceiling tile configurations illustrating exemplary configurations for accommodating the insertion of a trim piece for preparing a customized ceiling tile.
• a conventional ceiling tile construction 10 may include a peripheral frame 12a with a plurality of spokes or cross-members 12b that extend between sections of the peripheral frame.
• the cross-members 12b tend to divide the cover layer 14 into a series of openings and when cut along, for example, line A-A', will leave unsupported portions of the cover layer along the periphery of the customized ceiling tile.
• the cross-members may have a generally uniform cross-section, FIG. 2A or may have a hollow (not shown), "T"-shaped (not shown) or a channel, FIG. 2B, configuration.
• FIG. 3 A An exemplary ceiling tile 100 according to the present invention is illustrated in FIG. 3 A and includes a peripheral frame 102 surrounding a single opening and a cover layer 104 extending across the opening and attached to the peripheral frame.
• the peripheral frame 102 may be attached to the cover layer 104 using an adhesive layer 106 or other suitable attachment means such as stitching, welding, stapling, crimping, pressing, retaining, clipping or other mechanical and/or frictional attachments (not shown).
• the cross-sectional configuration of the frame may have an "S" or "Z” configuration, or may utilize a more complex configuration, that includes an inwardly extending offset portion of the peripheral frame 102 that, in combination with the cover layer 104 or another protruding portion of the frame (not shown), forms a peripheral recess 103.
• an exemplary ceiling tile 100 may be modified using a trim element or piece 108 that extends from one portion of the peripheral frame 102 to another portion of the peripheral frame and extends at least partially into the recess 103 at both ends.
• the trim element 108 will typically be attached to the portion of the cover layer 104 that is covered by the trim element with an adhesive layer 110.
• Premanufactured trim elements 108 may include a double-sided adhesive tape with a cover layer that is removed before application to expose an adhesive surface.
• the adhesive layer 110 may also be field-applied and may or may not be continuous, but the adhesive means utilized will preferably be one that will not degrade the appearance of the exposed surface of the cover layer 104, that is, will not discolor, seep or be extruded through the cover layer during application or during the anticipated useful life of the customized ceiling tile.
• the trim element 108 and the adhesive layer 110 can provide substantially continuous support for the cut edge of the remaining portion of the cover layer 104a, thus reducing sagging or wrinkling that would tend to degrade the appearance of the remaining portion of the ceiling tile 100a.
• the trim element 108 may be configured for customizing a ceiling tile 100a for placement around a generally rectangular obstruction.
• the trim element 108 may be formed by attaching two straight trim elements, as illustrated in FIG. 5 A, with mitered (shown), butt, overlapping or other attachment at the intersection of the two trim elements.
• premanufactured trim elements defining one or more common angles, such as 30°, 45°, 60° or 90°, to reduce the need for and/or to simplify the field assembly of more complex trim elements for customizing the ceiling tiles.
• FIG. 5 A the trim element 108 may be configured for customizing a ceiling tile 100a for placement around a generally rectangular obstruction.
• the trim element 108 may be formed by attaching two straight trim elements, as illustrated in FIG. 5 A, with mitered (shown), butt, overlapping or other attachment at the intersection of the two trim elements.
• premanufactured trim elements defining one or more common angles, such as 30°, 45°, 60° or 90°, to reduce the need for and/
• premanufactured trim elements 108 may be provided in curved, circular or arcuate configurations having an assortment of radii to reduce the need for and/or to simplify the field assembly of customized ceiling tiles for accommodating pipes, columns or other obstructions having a generally cylindrical or rounded surface.
• exemplary ceiling tiles 100 may be laid in a supporting structure or grid formed from a plurality of supporting members 200 that provide a supporting flange 202 on which an edge of the ceiling tile can rest.
• the supporting flange 202 has a surface 202a that is completely exposed when the ceiling tiles 100 are in place.
• the end portion of trim element 108 may also be provided with a recess 109 that allows it to engage the offset portion of the peripheral frame 102 and thereby reinforce the attachment.
• FIG. 7 A also illustrates both the optional use of a lower inwardly protruding portion of the peripheral frame 102 to form at least portion of the recess, thereby providing additional mechanical support for the end portion of the trim element 108, and the use of reinforced regions 108a provided on appropriate surfaces of the trim element that may, for example, improve the strength, durability and/or dimensional control of the ends of the trim elements.
• the peripheral frame 102 can be provided with extended portions 102c that extend across and below a portion of the exposed surface of the supporting flange 202.
• the peripheral frame can also be provided with resilient or otherwise biased retaining elements or members 112 that project generally upwardly from the peripheral frame and are configured for removably attaching the ceiling tile to the supporting grid.
• the retaining elements 112 may be configured to allow deflection or rotation, about either a horizontal or a vertical axis, between an attached position and a released position 112a to allow insertion and removal of the ceiling tile from the supporting grid.
• Openings may be provided in the peripheral frame 102 for inserting a tool or a finger through the frame to contact and deflect the retaining element 112.
• the openings may, in turn, be concealed using a plug or an insert 102d for concealing the openings until needed.
• the peripheral frame 102 may incorporate a simple mechanism 116 for deflecting the retaining element 112 through actuation of an exposed button, slide, tab, fastener or other structure.
• the peripheral frame may incorporate projections 102b, which may extend from the extended portion 102c of the peripheral frame and may be positioned below and/or spaced inwardly from the supporting flange 202.
• a plug or cover element may be provided for concealing the exposed portion of the mechanism until access is needed for actuation.
• an exemplary ceiling tile according to the invention will tend to include certain structural elements and dimensions that may be adapted as necessary to provide the strength and sizing appropriate for an intended application.
• the offset portion of the frame may have a characteristic length F and thickness To and be separated from the cover layer 104 by a recess height D.
• the supporting portion of the frame may have a characteristic length B and thickness Ts with the supporting portion of the frame and the offset portion of the frame being separated by a transitional or intermediate portion of length I.
• the peripheral frame 102 may be provided with one or more recesses 118 into which a corresponding attachment element 120 may be inserted or snapped to secure the cover layer 104 to the frame and/or improve the aesthetic appearance of the ceiling tile.
• the peripheral frame 102 may be provided with one or more reinforcing members 122 for increasing the strength and/or rigidity of the peripheral frame, thereby decreasing the quantity of material, typically a polymeric material, needed to obtain the desired strength and/or dimensions.
• the support surface, with or without a portion of the cover layer 104 can rest on the supporting flange 202, as illustrated in FIGS. 8C-8E, the peripheral frame 102 may be provided with an extended portion to provide a mounting surface 124 that is offset from the supporting surface, allowing the cover layer 104 to be positioned at different levels, that is, above or below, relative to the supporting flange. As illustrated in FIGS.
• the cover layer 104 may include an additional peripheral portion 104b that extends beyond the support surface and can be attached to the peripheral frame along one or more remote surfaces 102e that are offset from the support surface. These configurations allow the cover layer to conceal more of the peripheral frame and may be used to improve the appearance of the ceiling panel.
• an exemplary embodiment of a customized ceiling panel will include an end portion of a trim element 108 that extends into the recess defined between the offset portion of the peripheral frame 102 and the cover layer 104 and may be attached to the cover layer using an adhesive layer 110.
• the basic embodiment of FIG. 9 A may be modified to incorporate stopping structures 126 for controlling the depth of the insertion of the trim element into the recess 103 and projecting structures such as teeth or ridges 128 for improving the retention of the trim element within the recess.
• FIG. 9C the basic embodiment of FIG.
• 9A may also be modified to include a weakened or more resilient portion 130 that will allow the projecting portion of the offset portion of the peripheral frame 102 to be deflected to increase the sizing of the recess to simplify insertion of the end portion of the trim element 108 after which the offset portion can return to its original position.
• cover layer has generally been described as a single element, the invention may be adapted to incorporate a plurality of cover layers, that may be the same or different, to allow the designer, engineer or user to adapt one or more properties of the ceiling tile, such as appearance, strength, opacity and/or acoustical performance.
• cover layer may be attached, adjacent or separated configurations relative to any adjacent layer(s).
• the cover layers may be in a generally parallel orientation or one or more of the cover layers may have a more complex configurations, such as corrugations or catenary portions suspended between supporting elements.
• certain aspects of the various disclosed exemplary embodiments could be used in combination with aspects of any of the other disclosed embodiments or their alternatives to produce additional, but not herein illustrated, embodiments incorporating the claimed invention but more closely adapted for an intended use or performance requirements. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

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• 2005
  • 2005-01-31 US US11/047,313 patent/US20060179765A1/en not_active Abandoned
• 2006
  • 2006-01-27 KR KR1020077017709A patent/KR20080012824A/ko not_active Application Discontinuation
  • 2006-01-27 EP EP06719853A patent/EP1844202A1/de not_active Withdrawn
  • 2006-01-27 WO PCT/US2006/003183 patent/WO2006083759A1/en active Application Filing
  • 2006-01-27 CN CNA2006800036280A patent/CN101111649A/zh active Pending
  • 2006-01-27 JP JP2007553314A patent/JP2008528841A/ja not_active Abandoned
  • 2006-01-27 CA CA002592789A patent/CA2592789A1/en not_active Abandoned

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