US20210025165A1

US20210025165A1 - Decorative ceiling beam

Info

Publication number: US20210025165A1
Application number: US16/938,062
Authority: US
Inventors: Marc Hurtubise; Jerry Chabot; Fuzhong LIU; Luc Titley; Sean Cadney
Original assignee: Moulure Alexandria Moulding Inc
Current assignee: Moulure Alexandria Moulding Inc
Priority date: 2019-07-25
Filing date: 2020-07-24
Publication date: 2021-01-28
Also published as: CA3050571A1

Abstract

In at least one embodiment, the present invention provides a decorative ceiling beam assembly having a longitudinally extending reversible base plate, a longitudinally extending first side wall portion, a longitudinally extending second side wall portion and a longitudinally extending reversible bottom plate such that the components interfit to create a longitudinally extending, rectangularly prismatic decorative ceiling beam having a hollow cross section.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to Canadian Patent Application No. 3050571 filed on Jul. 25, 2019, which is herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to residential and commercial construction components. More specifically, the present invention relates to a decorative ceiling beam assembly that can be installed in new construction, renovation and redecoration applications.

BACKGROUND OF THE INVENTION

In both new construction and renovation projects, residential and commercial interior designers commonly employ decorative elements that mimic structural components for a variety of reasons.
False structural elements can be used to diminish the visual appearance of existing structural components, can provide visual or functional features, can be easily installed at reduced costs and can be used in connection with an overall design strategy to provide routing for ducting, tubing, wiring and plumbing in a visually attractive manner as the particular project requires.
One example of such false structural elements are decorative beam assemblies. Purely decorative (as opposed to structural) beam assemblies can be used to hide construction seams and underlying irregular features and are often hollow which provides a conduit for piping, ducting or electrical wiring as discussed above. Such decorative beams can also provide a sturdy mounting surface for ceiling fans and lighting fixtures. These relatively lightweight decorative assemblies can mimic the appearance of much more expensive steel or solid wood structural components and can be quickly and easily installed on site.
For example, U.S. Pat. No. 4,718,213 to Butterfield discloses a hollow section, decorative beam that consists of a three-walled decorative beam component that is sufficiently flexible such that inwardly projecting flanges can be fitted around corresponding outwardly projecting flanges provided on a base plate that is flushly mounted to the ceiling. Moreover, U.S. patent application Ser. No. 12/016,993 to Bryant discloses a hollow section, multi-component, non-structural decorative beam.
However, there is need for decorative beam assemblies that are sufficiently flexible in their design in order to provide a number of aesthetic appearances using the same fundamental components.
Moreover, there is need for decorative beam assemblies that are constructed of lightweight and economical materials and which can be securely installed yet readily removed when required without requiring extensive mechanical fasteners or high-strength adhesives.

BRIEF SUMMARY

It is contemplated that the present invention provides a decorative ceiling beam assembly that is lightweight, can be securely installed yet readily removed without requiring extensive mechanical fasteners and which provides a versatile aesthetic appearance that can be varied depending on the needs of the particular end user application.
In at least one embodiment it is contemplated that the present invention provides a decorative ceiling beam assembly having a longitudinally extending reversible base plate having a longitudinally extending first edge and a longitudinally extending second edge, the longitudinally extending first edge having a first longitudinally extending parallel and spaced apart outwardly projecting flange thereby defining a longitudinally extending outwardly opening first upper groove therebetween, the longitudinally extending second edge having a second longitudinally extending parallel and spaced apart outwardly projecting flange thereby defining a longitudinally extending outwardly opening second upper groove therebetween, a longitudinally extending first side wall portion having a longitudinally extending first upper edge and a longitudinally extending first lower edge, the first upper edge having a longitudinally extending inwardly projecting first upper flange, the longitudinally extending first side wall portion having a longitudinally extending first lower edge, the first lower edge having a longitudinally extending inwardly projecting first lower flange, a longitudinally extending second side wall portion having a longitudinally extending second upper edge and a longitudinally extending second lower edge, the second upper edge having a longitudinally extending inwardly projecting second upper flange, the longitudinally extending second side wall portion having a longitudinally extending second lower edge, the second lower edge having a longitudinally extending inwardly projecting second lower flange, and a longitudinally extending reversible bottom plate having a longitudinally extending first edge and a longitudinally extending second edge, the longitudinally extending first edge having a longitudinally extending first parallel and spaced apart outwardly projecting flange thereby defining a longitudinally extending outwardly opening first lower groove therebetween, the longitudinally extending second edge having a second longitudinally extending parallel and spaced apart outwardly projecting flange thereby defining a longitudinally extending outwardly opening second lower groove therebetween, such that the first upper groove of the reversible base plate securely receives at least one of the longitudinally extending inwardly projecting first upper flange of the first side wall portion and the longitudinally extending inwardly projecting first upper flange of the second side wall portion, the second upper groove of the reversible base plate securely receives the other of the longitudinally extending inwardly projecting second upper flange of the first side wall portion and the longitudinally extending inwardly projecting second upper flange of the second side wall portion and the outwardly opening first lower groove of the bottom plate receives one of the inwardly projecting first lower flange of the first side wall portion and the inwardly projecting second lower flange of the second side wall portion and the outwardly opening second lower groove of the bottom plate receives the other of the inwardly projecting first lower flange of the first side wall portion and the inwardly projecting second lower flange of the second side wall portion so as to create a rectangularly prismatic, longitudinally extending decorative ceiling beam.

DESCRIPTION OF THE DRAWINGS

The present invention will be readily understood in connection with the following Figures, in which:

FIG. 1 is a cross-sectional view of a decorative beam component attached to a mounting surface in accordance with at least one embodiment of the present invention;

FIG. 2 is a cross-sectional view of the decorative beam component of FIG. 1 in an alternative configuration; and

FIG. 3 is a cross-sectional view of the decorative beam component of FIG. 1 in yet another alternative configuration wherein the beam component is not mounted to an overhead surface; and

FIG. 4 is a close-up cross-sectional view of the connection interface between a side wall and the reversible bottom plate of the decorative beam component of FIG. 1.

DETAILED DESCRIPTION OF THE EMBODIMENT

It is contemplated that the present invention provides a decorative ceiling beam assembly that is lightweight, can be securely installed yet readily removed without requiring extensive mechanical fasteners and which provides a versatile aesthetic appearance that can be varied depending on the needs and available mounting surfaces of the particular end user application.
As will be readily understood by the skilled person, the components of the present invention can be manufactured out of any suitable material including but not limited to galvanized steel, aluminum, wood, PVC and various composite plastics. Moreover, it is contemplated that the components of the present invention can be separate, individual component suitable joined together or alternatively can be a single unitary component as appropriate.
It will also readily be appreciated that the components of the present invention can be formed of any suitable manufacturing method including but not limited to milling and planing, extrusion, 3-D printing, casting, stamping, bending and traditional woodworking among any other suitable manufacturing techniques that will be readily appreciated by the skilled person.
The present invention provides a decorative ceiling beam assembly having a longitudinally extending reversible base plate, a longitudinally extending first side wall portion, a longitudinally extending side second wall portion and a longitudinally extending reversible bottom plate such that the components interfit to create a longitudinally extending, rectangularly prismatic, decorative ceiling beam assembly having a hollow cross-section.
The longitudinally extending reversible base plate extends laterally between a longitudinally extending first edge and a longitudinally extending second edge. Each longitudinally extending edge further includes a longitudinally extending downwardly projecting flange. In some embodiments the downwardly projecting flanges are oriented generally perpendicularly to the reversible base plate however other arrangements are also contemplated.
In some embodiments it is contemplated that the longitudinally extending reversible base plate is similarly reversible in an analogous manner as the reversible bottom plate.
In these embodiments, it is contemplated that the longitudinally extending edges of the longitudinally extending reversible base plate are chamfered, however other arrangements are al so contemplated.
It is further contemplated that each longitudinally extending edge of the longitudinally extending reversible base plate has a longitudinally extending parallel and spaced apart outwardly projecting flange, thereby a defining a longitudinally extending outwardly opening groove between each longitudinally extending edge and each respective longitudinally extending flange.
In some embodiments, it is contemplated that the distal edge of the outwardly projecting flange is chamfered, however other arrangements are also contemplated.
In at least one embodiment, it is contemplated that the longitudinally extending outwardly opening grooves further include a longitudinally extending first groove wall and a longitudinally extending parallel and opposed second groove wall. In at least one embodiment, it is contemplated that the groove walls can further include longitudinally extending securing ridges.
As a result, it is contemplated that when the inwardly projecting flange of the side wall portion (discussed below) is inserted into the respective outwardly opening groove of the longitudinally extending reversible base plate, the longitudinally extending securing ridges of the tab walls can frictionally engage the longitudinally extending securing ridges of the adjacent groove walls. As a result, the side wall portion is frictionally yet releasable secured to the longitudinally extending reversible base plate, as will be discussed in further detail below.
In some embodiments, it is contemplated that the reversible base plate can further include a number of boreholes that can be used to mount the reversible base plate to a mounting surface by way of a mechanical fastener, such as a screw or bolt, among other arrangements that are readily understood by the skilled person. In other embodiments, it is contemplated that boreholes can be located in any other component of the present invention, thereby providing nearly unlimited flexibility in how the present decorative beam assembly can be mounted to an available surface.
It is further contemplated that the longitudinally extending first and second side wall portions are analogous to one another and extend between a longitudinally extending upper edge and a longitudinally extending lower edge.
It is further contemplated that each longitudinally extending upper edge and each longitudinally extending lower edge of each side wall portion further includes a longitudinally extending inwardly projecting flange. In some embodiments, the inwardly projecting flange is oriented generally perpendicular to the side wall portion however other arrangements are also contemplated.
In some embodiments the inwardly projecting flanges further include a longitudinally extending first sloped portion and an opposed longitudinally extending second sloped portion that defines a longitudinally extending tab element therebetween. It is contemplated that the longitudinally extending tab element can further include a longitudinally extending first tab wall and a longitudinally extending parallel and opposed second tab wall and a longitudinally extending distal tab edge joining these two tab walls together.
In some embodiments it is contemplated that the distal tab edge has a doubly chamfered, rounded, semi-obround or semi-circular cross-sectional profile, however other arrangements are also contemplated. Moreover, it is contemplated that each tab wall can further include at least one longitudinally extending securing ridge, as will be discussed in further detail below.
It is contemplated that the longitudinally extending reversible bottom plate is analogous to the reversible base plate and extends transversely between a longitudinally extending first edge and a longitudinally extending second edge. In some embodiments, it is contemplated that the longitudinally extending edges of the reversible bottom plate are chamfered, however other arrangements are also contemplated.
It is further contemplated that each longitudinally extending edge of the reversible bottom plate has a longitudinally extending parallel and spaced apart outwardly projecting flange, thereby a defining a longitudinally extending outwardly opening groove between each longitudinally extending edge and each respective longitudinally extending flange.
In some embodiments, it is contemplated that the distal edge of the outwardly projecting flange is chamfered, however other arrangements are also contemplated.
In at least one embodiment, it is contemplated that the longitudinally extending outwardly opening grooves further include a longitudinally extending first groove wall and a longitudinally extending parallel and opposed second groove wall. In at least one embodiment, it is contemplated that the groove walls can further include at least one longitudinally extending securing ridge.
As a result, it is contemplated that when the inwardly projecting flange of the side wall portion is inserted into the respective outwardly opening groove of the reversible bottom plate, the longitudinally extending securing ridges of the tab walls can frictionally engage the longitudinally extending securing ridges of the adjacent groove walls. As a result, the side wall portion is frictionally yet releasable secured to the reversible bottom plate, as will be discussed in further detail below.
In this way, in some embodiments it is contemplated that the reversible base plate can be secured to a surface, such as a ceiling, by way of a mechanical fastener inserted through a provided bore hole into the underlying surface.
Next, it is contemplated that the upper inwardly projecting flanges of the side wall portions can be received in the respective outwardly opening grooves provided in the reversible base plate in a secure but releasable manner.
Next, it is contemplated that the lower inwardly projecting flanges of the side wall portions can be received in the respective outwardly opening grooves provided in the reversible bottom plate in a secure but releasable manner.
As will be further appreciated by the skilled person, given the geometry of the inwardly projecting flanges of the side wall portions and the outwardly opening grooves of the reversible base plate and the reversible bottom plate, both the reversible base plate and the reversible bottom plate are in fact reversible about a central longitudinal axis in order to provide two different aesthetic profiles depending on the needs of the particular end user application.
Moreover, in embodiments where the edges of the interfitting components are chamfered, the skilled person will readily appreciate that the various chamfered male components will fit more readily into the various corresponding female components during installation given the additional angular movement that is permitted.
As a result, the longitudinally extending reversible base plate, the longitudinally extending first side wall portion, the longitudinally extending second side wall portion and the longitudinally extending reversible bottom plate interfit to create a longitudinally extending, rectangularly prismatic decorative ceiling beam having a hollow cross section.
With reference to FIGS. 1, 2, 3 and 4, one embodiment of a decorative ceiling beam assembly is illustrated. In this embodiment, decorative ceiling beam assembly 10 has a longitudinally extending reversible base plate 12, a longitudinally extending first side wall portion 14, a longitudinally extending side second wall portion 16 and a longitudinally extending reversible bottom plate 18 such that the components interfit to create a longitudinally extending, rectangularly prismatic, decorative ceiling beam assembly having a hollow cross-section.
Longitudinally extending reversible base plate 12 extends laterally between a longitudinally extending first edge 20 and a longitudinally extending second edge 22. In this embodiment, it is contemplated that the longitudinally extending edges 20, 22 of the reversible base plate 12 are chamfered.
It is further contemplated that each longitudinally extending edge 20, 22 of reversible base plate 12 has a parallel and spaced apart longitudinally extending outwardly projecting flange 32, thereby defining a longitudinally extending outwardly opening groove 34 between each longitudinally extending edge 20, 22 and each respective longitudinally extending flange 32. In this embodiment, it is contemplated that the distal edge 37 of the outwardly projecting flange 32 is chamfered.
With reference to FIGS. 1, 2, 3 and 4, in this embodiment it is contemplated that longitudinally extending outwardly opening groove 34 further includes a first groove wall 35 and a parallel and opposed second groove wall 36. In at least one embodiment, it is contemplated that the groove walls can each further include at least one longitudinally extending securing ridge 38.
In this embodiment, it is contemplated that reversible base plate 12 includes a number of bore holes that can be used to mount reversible base plate 12 to amounting surface 11 by way of a mechanical fastener 13, such as a screw or bolt.
In this embodiment, it is contemplated that the longitudinally extending first side wall portion 14 and the longitudinally extending second side wall portion 16 extend between a longitudinally extending upper edge 40 and a longitudinally extending lower edge 42. In this embodiment, it is contemplated that the longitudinally extending upper edge 40 and longitudinally extending lower edge 42 are chamfered on an inner surface.
With reference to FIGS. 1, 2, 3 and 4 it is further contemplated that each longitudinally extending upper edge 40 and lower edge 42 of the side wall portions 14, 16 further include a longitudinally extending inwardly projecting flange 50. In this embodiment, inwardly projecting flange 50 is oriented generally perpendicularly to side wall portion 14, 16.
In this embodiment the inwardly projecting flange 50 further includes a longitudinally extending first sloped portion 52 and an opposed longitudinally extending second sloped portion 54 that defines a longitudinally extending tab element therebetween. It is contemplated that the longitudinally extending tab element can further include a longitudinally extending first tab wall 57 and a parallel and opposed longitudinally extending second tab wall 58 and a longitudinally extending distal tab edge 59 joining these two tab walls together, as can be seen in FIG. 4.
In this embodiment, it is contemplated that the distal tab edge 59 has a semi-obround cross sectional profile. Moreover, it is contemplated that each tab wall 57, 58 can further include at least one longitudinally extending securing ridge 60, as will be discussed in further detail below.
As a result, it is contemplated that when inwardly projecting flange 50 of side wall portion 14, 16 is inserted into the respective outwardly opening groove 34 of reversible base plate 12, longitudinally extending securing ridge 60 of the tab walls 57, 58 can frictionally engage the longitudinally extending securing ridge 38 of the adjacent groove walls 35, 36. As a result, side wall portion 14, 16 is frictionally yet releasably secured to reversible base plate 12, as can be seen in FIG. 4.
It is further contemplated that longitudinally extending reversible bottom plate 18 is analogous to longitudinally extending base plate 12 and extends laterally between a longitudinally extending first edge 70 and a longitudinally extending second edge 72. In this embodiment, it is contemplated that the longitudinally extending edges 70, 72 of reversible bottom plate 18 are chamfered.
It is further contemplated that each longitudinally extending edge 70, 72 of reversible bottom plate 18 has a parallel and spaced apart longitudinally extending outwardly projecting flange 32, thereby defining a longitudinally extending outwardly opening groove 34 between each longitudinally extending edge 70, 72 and each respective longitudinally extending flange 32. In this embodiment, it is contemplated that the distal edge 37 of the outwardly projecting flange 32 is chamfered.
With reference to FIGS. 1, 2, 3 and 4 in this embodiment it is contemplated that longitudinally extending outwardly opening groove 34 further includes a first groove wall 35 and a parallel and opposed second groove wall 36. In at least one embodiment, it is contemplated that the groove walls further include at least one longitudinally extending securing ridge 38.
As a result, it is contemplated that when inwardly projecting flange 50 of side wall portion 14, 16 is inserted into the respective outwardly opening groove 34 of reversible bottom plate 18, longitudinally extending securing ridge 60 of the tab walls 57, 58 can frictionally engage the longitudinally extending securing ridge 38 of the adjacent groove walls 35, 36. As a result, side wall portion 14, 16 is frictionally yet releasably secured to reversible bottom plate 18.
In this way, in some embodiments it is contemplated that reversible base plate 12 can be secured to surface 11, such as a ceiling, by way of mechanical fastener 13 inserted through a provided bore hole into the underlying surface 11 as can be seen in FIG. 1.
Next, side wall portions 14, 16 can be positioned so that upper inwardly projecting flanges 50 of side wall portions 14,16 can be received in the respective outwardly opening grooves 34 provided in reversible base plate 12 in a secure but releasable manner
Next, it is contemplated that lower inwardly projecting flanges 51 of side wall portions 14, 16 can be received in the respective outwardly opening grooves 34 provided in reversible bottom plate 18 in a secure but releasable manner.
As will be further appreciated by the skilled person, given the geometry of inwardly projecting flanges 50 of side wall portions 14, 16 and outwardly opening grooves 34 of reversible base plate 12 and outwardly opening grooves 34 reversible bottom plate 18, both reversible base plate 12 and reversible bottom plate 18 are in fact reversible about a central longitudinal axis in order to provide multiple different aesthetic profiles depending on the needs of the particular end user application.
As a result, longitudinally extending reversible base plate 12 longitudinally extending first side wall portion 14, longitudinally extending second side wall portion 16 and longitudinally extending reversible bottom plate 18 interfit to create decorative ceiling beam assembly 10.
While the present invention has been described with reference to particular embodiments it will be apparent to anyone skilled in the art that there are many permutations and combinations of combining the primary response variables to achieve particular benefits. All such permutations and combinations are considered to be within the sphere and scope of this invention as defined in the claims appended hereto.

Claims

What is claimed is:

1. A decorative ceiling beam assembly comprising:

A longitudinally extending reversible base plate having a longitudinally extending first edge and a longitudinally extending second edge, the longitudinally extending first edge having a first longitudinally extending parallel and spaced apart outwardly projecting flange thereby defining a longitudinally extending outwardly opening first upper groove therebetween, the longitudinally extending second edge having a second longitudinally extending parallel and spaced apart outwardly projecting flange thereby defining a longitudinally extending outwardly opening second upper groove therebetween;

A longitudinally extending first side wall portion having a longitudinally extending first upper edge and a longitudinally extending first lower edge, the first upper edge having a longitudinally extending inwardly projecting first upper flange, the first lower edge having a longitudinally extending inwardly projecting first lower flange;

A longitudinally extending second side wall portion having a longitudinally extending second upper edge and a longitudinally extending second lower edge, the second upper edge having a longitudinally extending inwardly projecting second upper flange, the second lower edge having a longitudinally extending inwardly projecting second lower flange; and

A longitudinally extending reversible bottom plate having a longitudinally extending first edge and a longitudinally extending second edge, the longitudinally extending first edge having a longitudinally extending first parallel and spaced apart outwardly projecting flange thereby defining a longitudinally extending outwardly opening first lower groove therebetween, the longitudinally extending second edge having a second longitudinally extending parallel and spaced apart outwardly projecting flange thereby defining a longitudinally extending outwardly opening second lower groove therebetween;

wherein the first upper groove of the reversible base plate securely receives at least one of the longitudinally extending inwardly projecting first upper flange of the first side wall portion and the longitudinally extending inwardly projecting first upper flange of the second side wall portion, the second upper groove of the reversible base plate securely receives the other of the longitudinally extending inwardly projecting second upper flange of the first side wall portion and the longitudinally extending inwardly projecting second upper flange of the second side wall portion and the outwardly opening first lower groove of the bottom plate receives one of the inwardly projecting first lower flange of the first side wall portion and the inwardly projecting second lower flange of the second side wall portion and the outwardly opening second lower groove of the bottom plate receives the other of the inwardly projecting first lower flange of the first side wall portion and the inwardly projecting second lower flange of the second side wall portion so as to create a rectangularly prismatic, longitudinally extending decorative ceiling beam.

2. The decorative ceiling beam assembly of claim 1 wherein at least one of the first inwardly projecting upper flange, the second inwardly projecting upper flange, the first inwardly projecting lower flange and the second inwardly projecting lower flange further comprises a longitudinally extending first sloped portion and an opposed longitudinally extending second sloped portion defining a longitudinally extending tab element therebetween, the longitudinally extending tab element having a longitudinally extending first tab wall and a parallel and opposed longitudinally extending second tab wall and a longitudinally extending tab edge.

3. The decorative ceiling beam assembly of claim 2 wherein the cross-sectional shape of the longitudinally extending tab edge is semi-obround.

4. The decorative ceiling beam assembly of claim 2 wherein at least one of the first tab wall and the second tab wall further include at least one longitudinally extending securing ridge.

5. The decorative ceiling beam assembly of claim 1 wherein at least one of the first edge and the second edge of the reversible bottom plate are chamfered.

6. The decorative ceiling beam assembly of claim 1 wherein at least one of the first edge and the second edge of the reversible base plate are chamfered.

7. The decorative ceiling beam assembly of claim 1 wherein a distal edge of at least one of the first parallel and spaced apart outwardly projecting flange of the reversible bottom plate, the second parallel and spaced apart outwardly projecting flange of the reversible bottom plate, the first parallel and spaced apart outwardly projecting flange of the reversible base plate and the second parallel and spaced apart outwardly projecting flange of the reversible base plate are chamfered.

8. The decorative ceiling beam assembly of claim 1 wherein at least one of the first groove and the second groove of the reversible bottom plate and the first groove and the second groove of the reversible base plate further comprises a longitudinally extending first groove wall and a longitudinally extending parallel and opposed second groove wall, at least one of the first groove wall and the second groove wall further including at least one longitudinally extending securing ridge.

9. The decorative ceiling beam assembly of claim 1 wherein the decorative ceiling beam assembly is comprised of extruded plastic components.