JP2008528841A - Adaptable ceiling tile system - Google Patents

Abstract

An adaptable ceiling tile that can be incorporated into a ceiling tile system.
An adaptable ceiling tile structure and a suspended ceiling system using such a ceiling tile are disclosed. A cover layer (104), such as fabric or rough cloth, is pulled across the opening and attached to a frame with a support surface that forms the main plane of the cover layer and an offset portion that forms a peripheral recess (103) It is done. Ceiling tiles can accommodate special orders using prefabricated trim pieces having an end configured to be inserted into the peripheral recess and an intermediate portion attached to the cover layer. Once the trim piece is in place, a portion of the peripheral frame and cover layer is typically removed by cutting to complete a custom ceiling tile.
[Selection] Figure 5A

Description

  The present invention relates to a suspended ceiling with a plurality of ceiling tiles supported by a structural grid, and more particularly to an improved fit to other surrounding structures and obstacles when installing the suspended ceiling. The present invention relates to an improved suspended ceiling system with built-in ceiling tiles.

  A number of systems and structures have been developed for providing drop ceilings or suspended ceilings in rooms. As will be appreciated by those skilled in the art, suspended ceilings are for finishing spaces that are spaced from the main overhead structure, such as ceiling beams or the underside of a reinforced concrete structure to establish a substantial level. The ceiling is more aesthetic. Suspended ceilings provide improved flexibility to finish the space on the main overhead structure or the ceiling system that is directly attached to furring strips or other attachment areas provided on the main overhead structure. Suspended ceilings typically have a plurality of individual ceiling tiles with rectangular or square individual tiles.

  The individual ceiling tile formulations used in such systems are also made from many different materials such as pressed fiber material or synthetic polymers and synthetic resins that are cast to form the tile body. The ceiling tile can also be provided with at least one embossed or textured surface to improve aesthetic appearance and / or sound absorption. Other types of ceiling tiles can be manufactured using a combination of a frame and a cover layer provided on and supported by the frame. 1, 2A and 2B show one structure of a conventional ceiling tile that incorporates a frame and cover layer.

  Conventional suspended ceiling systems typically use a track system or grid assembly to support individual tiles. It will be appreciated that proper installation of ceiling tiles, grid assemblies and tiles is generally limited to a relatively narrow range of geometric conditions. Conventional assemblies have a shape that forms alternating rows or columns in which the exposed surfaces of the ceiling tiles are generally in a single plane and are offset by a predetermined uniform distance from adjacent columns. Are arranged in a regular array of rows and columns. In any case, the ceiling tiles are generally arranged such that a uniform pattern is created.

  Suspended ceilings also allow one or more methods to adapt grid assemblies and ceiling tiles to, for example, ceiling space corners, pipes, ducts, pillars, etc., and obstacles or other changes in the surrounding ceiling space profile. Must be obtained. In one conventional suspended ceiling system, a wall angle molding is attached to the inner periphery of the wall at a height defined for the grid assembly. The grid assembly is then built using an inverted “T” element that is aligned with and attached to the wall angle molding. In most cases, the grid elements are made of metal and must be cut using a gold cutter, punching tool or other suitable cutting instrument, so any burrs and sharp edges will be removed before installation. It must be scraped off with a file.

  Conventional suspended ceiling constructions using “T-bar” and “Z-bar” suspension elements that form a grid that supports the ceiling tiles have the flanges of the support grid elements exposed (this is the installation Degrading the aesthetic quality of the finished ceiling). This disadvantage can be addressed at least in part by using a finished metal surface, but the manufacturing costs are concomitantly increased. To address this problem, various concealed grid assembly T-bar structures have been developed, but many of these solutions are not easy to remove and provide access to suspended ceiling space. There are other problems including having to destroy one or more ceiling tiles. Other designs that access the space behind the ceiling incorporate additional latching structures and / or pivot structures that allow one or more key tiles to be shifted or rotated from an installed position to an “open” position.

  The present invention discloses an adaptable ceiling tile that can be incorporated into a ceiling tile system.

  The basic ceiling tile has a peripheral frame surrounding a single main opening, the peripheral frame being configured to form a main portion that forms a support surface and an offset portion that forms an offset surface. A cover layer, such as a woven or non-woven fabric or rough cloth, is pulled across the opening and attached to the frame. The support surface forms as a whole the plane of the portion of the cover layer that extends over the entire opening.

  A peripheral recess is formed between the cover layer and the offset surface of the frame. The ceiling tile then has one or more prefabricated trims having an end configured to be inserted into the peripheral recess and an intermediate portion attached to the support of the portion lying under the cover layer Special pieces are handled or matched using pieces. Once the trim piece is in place, a portion of the peripheral frame and cover layer is typically removed by cutting to complete a custom-made ceiling tile that incorporates the trim piece as the periphery of the modified tile.

  The trim pieces are offered as standard shapes within a certain range including straight, curved or angled so that installers can install ceiling tiles in a wide range of pipes and columns, such as pipes and columns that interfere with suspended ceiling profiles. Can be easily adapted to the structure.

  As will be described in more detail below, peripheral frames used for ceiling tiles are provided in a wide variety of forms. In one exemplary embodiment, the peripheral frame can be provided with extensions that conceal at least a portion of the lower surface of the support grid to reduce the visible spacing between adjacent ceiling tiles. The peripheral frame may also incorporate one or more releasable retaining structures or elements for temporarily attaching the ceiling tile to the support grid.

The features and advantages of the suspended ceiling system and adaptable ceiling tile according to the present invention generally described above will become more apparent from the following detailed description of exemplary embodiments of the invention and the accompanying drawings.
These and other features and advantages of the present invention will become more apparent from the detailed description of exemplary embodiments set forth below with reference to the accompanying drawings.

  The accompanying drawings are intended to assist in understanding the exemplary embodiments of the present invention described in detail below and should not be construed to unduly limit the present invention. More particularly, the relative spacing, relative position, sizing, and dimensional scale of the various elements shown are not necessarily accurate, and may be exaggerated, shortened, or modified for purposes of clarity.

  Those skilled in the art will also understand that a range of modifications has been omitted in order to increase the clarity of the drawings and reduce the number of drawings. Similarly, one of ordinary skill in the art will appreciate that some of the various structural elements shown in the exemplary embodiments shown in FIGS. 2A-9C form other structures to create a ceiling tile structure that can be tailored to the intended application. It will also be appreciated that combinations can be made selectively and independently.

Exemplary Embodiment As shown in FIG. 1, a conventional ceiling tile structure 10 has a peripheral frame 12a, which includes a plurality of spokes or cross members 12b extending between the sections. The cross member 12b divides the cover layer 14 into a series of openings, and leaves an unsupported portion of the cover layer along the periphery of the custom-made ceiling tile, for example, when viewed in cross section along the line AA ′. End up. As shown in FIGS. 2A and 2B, the cross member 12b has a substantially uniform cross section (FIG. 2A), or a hollow (not shown) “T” shaped structure (not shown) or channel structure (FIG. 2B). )have.

  An example ceiling tile 100 according to the present invention is shown in FIG. 3A, which includes a peripheral frame 102 surrounding a single opening and a cover layer extending across the opening and attached to the peripheral frame 102. 104. As shown in FIG. 3B, which is a cross-sectional view taken along the line AA ′ of FIG. 3A, the peripheral frame 102 is formed of an adhesive layer 106, or stitching, welding, stapling, caulking. the cover layer 104 using other suitable attachment means such as (crimping), pressing, retaining, retaining, clipping, or other mechanical and / or frictional attachments (not shown). Can be installed. The cross-sectional structure of the frame can be “S” shaped or “Z” shaped. Alternatively, the cross-sectional structure of the frame includes an offset portion extending inward of the peripheral frame 102 (this portion is combined with the cover layer 104 or another protrusion (not shown) of the frame to form the peripheral recess 103). More complex structures can be used.

  As shown in FIG. 4A, the exemplary ceiling tile 100 uses trim elements or trim pieces 108 that extend from a portion of the peripheral frame 102 to the other portion of the peripheral frame and at least partially extend into the recesses 103 at both ends. Can change. As shown in FIG. 4B, the trim element 108 is typically attached to a portion of the cover layer 104 covered by the trim element 108 using an adhesive layer 110. The pre-manufactured trim element 108 can be provided with a double-sided adhesive tape with a cover layer that is removed before exposing the adhesive surface. The adhesive layer 110 can be applied in-situ and may or may not be applied continuously. However, the adhesive means used does not detract from the appearance of the exposed surface of the cover layer 104, i.e., does not fade and oozes through the cover layer during application or during the expected useful life of a custom ceiling tile. Those which are not extruded are preferred.

  As shown in FIG. 5A, once the trim element 108 is in place and attached to at least a portion of the region of the underlying cover layer 104, the peripheral frame 102 and a portion of the cover layer 104 are removed. This allows the peripheral frame 102a and trim element 108 to form the periphery of a modified or custom ceiling tile 100a. As shown in FIG. 5B, the trim element 108 and the adhesive layer 110 can form a substantially continuous support at the cut edge of the remainder of the cover layer 104a, thereby detracting from the appearance of the remainder of the ceiling tile 100a. It is possible to reduce slack or wrinkles having a tendency.

  As shown in FIG. 6A, the trim element 108 can be configured to specifically order the ceiling tile 100a so that it can be placed around a generally oblong obstacle. The trim element 108 is formed by attaching two straight trim elements at the intersection of the two trim elements, as shown in FIG. 5A, using diagonal seams (as shown), butt, overlap or other attachments. it can. Similarly, more complex trim elements for custom-made ceiling tiles can be used in the field by using pre-manufactured trim elements that form one or more common angles such as 30 °, 45 °, 60 ° or 90 °. The need for assembly can be reduced and / or simplified. As shown in FIG. 6B, the prefabricated trim element 108 reduces the need for on-site assembly of specially ordered ceiling tiles to accommodate pipes, pillars or other obstacles with generally cylindrical or round surfaces. Can be formed into curved, circular, or arcuate shapes with various radii for simplicity and / or simplification.

  As shown in FIG. 7A, an exemplary ceiling tile 100 according to the present invention can be placed in a support structure or support grid formed from a plurality of support members 200 having support flanges 202 on which the edges of the ceiling tile rest. In the configuration shown in FIG. 7A, the support flange 202 has a surface 202a that is completely exposed when the ceiling tile 100 is placed in place. As also shown in FIG. 7A, the end of the trim element 108 can be provided with a recess 109 that can engage the offset portion of the peripheral frame 102 to enhance its attachment. 7A also uses a lower inward protrusion of the peripheral frame 102 to optionally form at least a portion of the recess, thereby forming an additional mechanical support at the end of the trim element 108. Both the use of reinforcing regions 108a provided on the appropriate surface of the trim element to improve the strength, durability and / or dimensional adjustment of the end of the trim element 108, for example.

  As shown in FIG. 7B, the peripheral frame 102 may be provided with an extension 102c that extends below a portion of the exposed surface of the support flange 202 and across a portion of the exposed surface. The peripheral frame 102 can also be provided with an elastic holding element (or member) or a pressure holding element (or member) 112. The holding element (or member) 112 protrudes upward as a whole from the peripheral frame, and is configured so that the ceiling tile can be detachably attached to the support grid. The retaining element 112 is configured to bend or rotate about a horizontal or vertical axis between the mounting and release positions so that the ceiling tile can be inserted or removed from the support grid. .

  The peripheral frame 102 can be provided with an opening through which a tool or finger can be contacted to bend the holding element 112 and bend it. This opening can be concealed with a plug or insert 102d to plug it. Instead of an opening, the peripheral frame 102 may incorporate a simple mechanism 116 that manipulates externally exposed buttons, slides, tabs, fasteners or other structures to bend the retaining element 112. Also, as shown in FIG. 7B, the peripheral frame can be provided with a protrusion 102b that extends from the peripheral frame extension 102c, below the support flange 202 and inwardly from the support flange. Can be arranged at intervals. As with the opening, a plug or cover element can be provided to conceal the exposed portion of the mechanism 116 except when access for operation is required.

  As shown in FIG. 8A, exemplary ceiling tiles according to the present invention can be provided with certain structural elements and dimensions that are adapted as needed to provide strength and sizing suitable for the intended application. As shown in FIG. 8A, the offset portion of the frame has a characteristic length F and thickness To and is separated from the cover layer 104 by a recess height D. The support part of the frame has a characteristic length B and a thickness Ts, and the support part and the offset part of the frame are separated by a transition or intermediate part of length I.

  As shown in FIG. 8B, the peripheral frame 102 can be provided with one or more recesses 118 in which the cover layer 104 is secured to the frame and / or improves the aesthetic appearance of the ceiling tile. A corresponding attachment element 120 can be inserted or fitted.

  As shown in FIG. 8C, the peripheral frame 102 is provided with one or more reinforcing members 122 to increase the strength and / or rigidity of the peripheral frame, thereby obtaining the desired strength and / or dimensions. As a material (generally a polymer material) necessary for this, a low quality material can be used. Also, as shown in FIG. 7A, the support surface (with or without the cover layer 104 portion) can be placed on the support flange 202, but as shown in FIGS. 8C-8E, The frame 102 is provided with an extension that forms a mounting surface 124 that is offset from the support surface that allows the cover layer 104 to be positioned at various levels relative to the support flange, ie, above or below the support flange. Can do.

  As shown in FIGS. 8E and 8F, the main plane of the cover layer 104 is generally formed by the peripheral frame 102, the modified peripheral frame 102a and the support surface (s) of one or more trim elements 108, The cover layer 104 can be provided with an additional peripheral portion 104b that is attached to the peripheral frame along one or more remote surfaces that extend beyond and are offset from the support surface. These structures can be used to allow the cover layer to conceal more peripheral frames and improve the appearance of the ceiling panel.

  As shown in FIG. 9A, one exemplary embodiment of a custom-made ceiling panel has the end of a trim element 108 extending into a recess formed between the offset portion of the peripheral frame 102 and the cover layer 104. And attached to the cover layer 104 using an adhesive layer 110. As shown in FIG. 9B, the basic embodiment of FIG. 9A provides a stopping structure 126 for adjusting the insertion depth of the trim element into the recess 103 and the retention of the trim element in the recess 103. And can be modified to incorporate protruding structures such as teeth or ridges 128. As shown in FIG. 9C, the basic embodiment of FIG. 9A can be modified to include a weakened portion or a more elastic portion 130. This weakened or more elastic portion 130 increases the sizing of the recess to simplify the insertion of the end of the trim element 108 and allows the offset portion to return to its original position after insertion. This is to allow the protruding portion of the offset portion 102 to be bent.

  Although the present invention has been described in connection with certain exemplary embodiments, it will be apparent to those skilled in the art that many changes can be made to the structure and method in a manner consistent with the detailed description. Let's go. More specifically, although the cover layer has been described as being a single element, the present invention provides one or more characteristics of a ceiling tile, such as appearance, strength, opacity and / or acoustic properties, by a designer, technician or user. A plurality of cover layers (the cover layers can be the same or different) can be incorporated. Where more than one cover layer is provided, the one or more layers can be attached in an adjacent or separate form to any adjacent layer (s). If more than one cover layer is used, the cover layers are arranged in parallel as a whole, or the one or more cover layers are suspended, for example, between corrugated parts or chained parts, like support parts A more complicated structure can be obtained. As will be apparent to one skilled in the art, certain aspects of the various disclosed exemplary embodiments may be used in combination with features of any of the other disclosed embodiments or variations thereof to claim the claimed invention. Additional embodiments not illustrated herein may be made that incorporate, but are more adapted to the intended use or performance conditions. Accordingly, the present invention is intended to embrace such various modifications as fall within the spirit and broad scope of the appended claims.

It is a top view which shows the conventional ceiling tile structure. It is sectional drawing of the conventional ceiling tile structure which follows the A-A 'line of FIG. It is sectional drawing which follows the A-A 'line of FIG. 1 is a plan view illustrating an exemplary ceiling tile structure according to the present invention. It is sectional drawing which follows the A-A 'line of FIG. 3A. 3B is a plan view illustrating an exemplary ceiling tile structure according to the present invention that is generally the same as the structure of FIGS. 3A and 3B except that a trim piece is added. FIG. It is sectional drawing which follows the A-A 'line of FIG. 4A. 5 is a plan view of an exemplary ceiling tile structure according to the present invention that is generally the same as the structure of FIGS. 4A and 4B, except that some of the original tiles have been removed to make a custom-made ceiling tile. FIG. It is sectional drawing which follows the A-A 'line of FIG. 5A. FIG. 3 is a plan view of an exemplary custom ceiling tile structure according to the present invention, with portions of the original tiles removed to make a custom ceiling tile. FIG. 3 is a plan view of an exemplary custom ceiling tile structure according to the present invention, with portions of the original tiles removed to make a custom ceiling tile. FIG. 6 is a cross-sectional view illustrating another example ceiling tile structure that supports ceiling tiles from a support frame or a support grid. FIG. 6 is a cross-sectional view illustrating another example ceiling tile structure that supports ceiling tiles from a support frame or a support grid. It is sectional drawing which shows another example ceiling tile structure. It is sectional drawing which shows another example ceiling tile structure. It is sectional drawing which shows another example ceiling tile structure. It is sectional drawing which shows another example ceiling tile structure. It is sectional drawing which shows another example ceiling tile structure. It is sectional drawing which shows another example ceiling tile structure. FIG. 6 is a cross-sectional view illustrating an exemplary ceiling tile structure illustrating an exemplary structure that can be adapted for insertion of trim pieces to create a custom ceiling tile. FIG. 6 is a cross-sectional view illustrating an exemplary ceiling tile structure illustrating an exemplary structure that can be adapted for insertion of trim pieces to create a custom ceiling tile. FIG. 6 is a cross-sectional view illustrating an exemplary ceiling tile structure illustrating an exemplary structure that can be adapted for insertion of trim pieces to create a custom ceiling tile.

Claims (19)

Having a ceiling tile (100) with a peripheral frame (102) forming a single main opening, the peripheral frame being configured to form a support surface and an offset surface;
A cover layer (104) extending over the support surface across the opening, the cover layer (104) cooperating with the offset surface to form a recess (103);
The adapter further comprising a trim element (108) having a portion configured to be inserted into the recess to form a small opening and a contact surface attachable to the cover layer (104). Bull ceiling tile system.   2. The adapter according to claim 1, wherein the cover layer is attached to the peripheral frame by one or more fixing methods selected from the group consisting of adhesion, stapling, welding, caulking, crimping, retaining and stitching. Bull ceiling tile system.   The adaptable ceiling tile system of claim 1, wherein the offset surface has a protruding structure (128) that holds an insertion portion of a trim element.   The adaptable ceiling tile system according to claim 1, wherein the peripheral frame is configured such that an offset surface can be bent in a direction away from the cover layer.   2. The adaptable ceiling tile system according to claim 1, wherein the cover layer is rough cloth (veil) and the peripheral frame is a polymer blend.   6. The adaptable ceiling tile system of claim 5, wherein the polymer blend has a reinforcing structure (122).   The adaptable ceiling tile system of claim 1, wherein the peripheral frame has a mounting surface (124), the mounting surface being offset from a support surface.   The peripheral frame includes a recess (118) adjacent to a support surface, the recess configured to receive a retainer element (120) that secures a cover layer to the peripheral frame. The described adaptable ceiling tile system. A retaining structure (112) extending in a direction substantially perpendicular to the direction of the cover layer;
2. The adaptable ceiling tile system according to claim 1, further comprising an access opening provided in a peripheral frame for bending the holding structure. A retaining structure (112) extending in a direction substantially perpendicular to the direction of the cover layer;
The adaptable ceiling tile system according to claim 1, characterized in that it comprises a bending element (116), the bending element being configured to bend the holding structure by moving it.   8. The adaptable ceiling tile system of claim 7, further comprising a peripheral frame extension (102c) to reduce the apparent separation between adjacent ceiling tiles.   The adaptable ceiling of claim 1, further comprising a stop element (126) extending from the offset surface to the cover layer to limit movement of the portion of the trim element into the recess. Tile system. In how to make a custom ceiling tile with a small opening,
Obtaining a basic ceiling tile (100), the basic ceiling tile having a peripheral frame (102) forming a single main opening, the peripheral frame being configured to form a support surface and an offset surface And further comprising a cover layer (104) extending over the support surface across the opening, the cover layer (104) cooperating with the offset surface to form a recess (103);
Determining the changes required in the main opening to form a small opening;
Configuring the trim element to create a small opening;
Inserting a portion of the trim element into the recess and attaching the contact surface to the cover layer to form a small perimeter;
Removing a portion of the peripheral frame and cover layer beyond a small periphery.   The method of claim 13, wherein the trim element is selected from a standard shape selected from the group consisting of a straight trim element, an angle trim element, and a curved trim element.   The method of claim 13, wherein the trim element is selected from a standard shape selected from the group consisting of a straight trim element, a right angle trim element, and an arcuate trim element. A suspension grid configured to support a plurality of basic ceiling tiles and special order ceiling tiles;
A basic ceiling tile with a regular polygonal perimeter formed by a perimeter frame (102) forming a single main opening, the perimeter frame being configured to form a support surface and an offset surface, the cover layer (104) extends across the opening and onto the support surface, and the cover layer cooperates with the offset surface to form a recess;
The custom-made ceiling tile has an irregular periphery, which constitutes a trim element (108), a part of the trim element is inserted into the recess (103), and the contact surface of the trim element is the cover layer Formed by modifying the basic ceiling tile by removing the peripheral frame and cover layer portions that extend beyond the irregular perimeter to form a custom perimeter tile that is attached Ceiling tile installation system characterized by.   The holding structure (112) provided on the ceiling tile further comprises a holding structure (112) that cooperates with the suspension grid to maintain the position of the installed ceiling tile. Item 16. A ceiling tile installation system according to item 16.   18. The ceiling tile installation system according to claim 17, wherein a peripheral frame of the ceiling tile is provided with an opening for accessing the holding structure and releasing the holding structure to remove the ceiling tile. .   17. The ceiling tile installation system according to claim 16, wherein the peripheral frame has an extension portion that conceals a part of the hanging grid and reduces a visible distance between adjacent tiles.

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