US3241280A - Panel supporting structure - Google Patents

Description

March 22, 1966 J. E. KREUZER 3,241,280

PANEL SUPPORTING STRUCTURE Filed Feb. 14, 1963 2 Sheets-Sheet 1 INVENTOR (/04 /u5 M95020? drrom/m s March 22, 1966 J. E. KREUZER PANEL SUPPORTING STRUCTURE 2 Sheets-Sheet 2 Filed Feb. 14, 1963 R R m 3 NU V WM 5 W M 5 um w A United States Patent 3,241,280 PANEL SUPPORTING STRUCTURE Julius E. Kreuzer, Pittsburgh, Pa., assignor to Owens- Corning Fiberglas Corporation, a corporation of Dela- Ware Filed Feb. 14, 1963, Ser. No. 258,437 6 Claims. (Cl. 52-311) Unsightly overhead ducts, piping and electrical wiring may be screened by the interposition of such a panel formation, and a decorative ceiling surface may thus be substituted for the irregular configurations derived from many present roof or permanent ceiling designs.

The rectangular panels forming these sub-ceilings present a neat appearance, and generally serve for noise abatement and.control. They are preferably composed of fibrous glass stock which has a superior noise reduction capacity, high thermal insulating characteristics and is valuable in lessening fire hazards.

The panelsfor which the supporting structure of this invention is especially intended are of a conventional type which have a density between one and one half and ten pounds per cubic foot and a thickness between three quarters of an inch and three inches.

Y The supporting structure for ceiling panels commonly includes an arrangement of inverted metal T-beams hung by Wires, rods or straps from joists or purlins with various intermediate reinforcing, members. The T-beams may be in intersecting lattice formation in which case the panels may be supported along all four edges upon flanges of the beams, Alternately, the beams may all run in the same direction in parallel, spaced sequence. The panels are then supported along one pair of opposite sides only, and the unsupported side edges of the panels abut edges of adjoining panels.

Ceiling panels of fibrous glass are of limited weight and yet have ample strength to maintain their shapes and positions in ordinary service. Due to their inorganic nature, such panels resist warping and sagging when subjected to water from leaks or condensation.

In view of the natural lightness and sturdiness of the panels, there is no special need of an extensive supporting system. However, various beams, auxiliary braces, and other members have been inserted between the building elements carrying the load and the rails or beams upon which the panels are laid. Besides these extra members, many installations also include special and intricate fastening devices to join the various elements together.

Such suspension systems are expensive and complicated particularly for residential use, but are also economically objectionable in stores, business ofiices and low cost in dustrial buildings.

Fibrous glass acoustical panels as well as such panels of other less effective compositions have been widely sold in great quantities for many years. While basically decorative, their appearance is no longer novel and may give a plain, unexciting impression. Support means for the panels have not been considered as contributing to an improvemet in eye appear and are often completely concealed as considered unsightly.

It is accordingly a prime object of this invention to provide an improved panel supporting structure that is particularly attractive and is a dominating decorative feature of the ceiling assembly.

It is a further object of this invention to provide a low cost supporting structure which may be easily and quickly installed and is light in weight, but still possesses suflicient strength and rigidity to maintain the panels in a level, orderly arrangement.

More specifically it is an object of this invention to provide a panel supporting structure utilizing hollow supporting beams simulating ornate, sturdy wooden beams. A further object is to provide simple hollow beams of corrugated paper board imprinted with a colored, natural wood grain effect.

A still further object is to provide such supporting structure which is particularly suited for installation in dens, family and recreation rooms of residences, club rooms, business ofiices, and small industrial buildings.

These and other objects and advantages of the invention are attained principally through the construction and use of corrugated paper beams having a hollow main body portion of preferably triangular or rectangular cross section and of substantial dimensions, with an upwardly extending flat Web or tongue member by which the beam may be suspended by wires or straps from elements of the permanent ceiling or root.

Other details and advantages of the supporting structure will be described in connection with the drawings in which:

FIGURE 1 is a perspective view of a blank of corrugated paper which is scored for bending into a beam incorporating one form of this invention;

FIGURE 2 is a perspective view of an end portion of a triangularly-bodied beam shaped from the paper blank of FIGURE 1;

FIGURE 3 is a perspective, partial view of an installation of acoustical panels utilizing beams like that shown in FIGURE 2;

FIGURE 4 is a perspective view of a modified form of triangular beam utilized as a cross beam in the installation of FIGURE 3;

FIGURE 5 shows a portion of an installation in which main beams and cross beams of rectangular cross section are the supporting members for the panels;

FIGURE 6 is a perspective view of a frame by which the ends of the cross beams of the installation of FIG- URE 5 are held in place;

FIGURE 7 illustrates the blank of corrugated paper from which the frame of FIGURE 6 is constructed;

FIGURE 8' shows a beam with a trapezoidal cross section; and

FIGURE 9 illustrates a beam of a semi-cylindrical cross section.

Referring to the drawings in more detail, in FIGURE 1 is shown a blank 12, eight inches wide and ten to fourteen feet long of corrugated paper board for shaping into a beam of triangular section embodying one torm of this invention, This blank is scored for bendmg longitudinally and the blank is thus divided into sections a, a, b, b, c and c.

The side of the blank destined to be on the inner or concealed side of the beam structure is faced with a sheet 14 of kraft paper stock weighing forty-two pounds per thousand square feet. Next .tothis is the corrugated kraft core or interliner 15 having a B flute corrugation, and on the opposite, or top side of the blank, as illustrated 'in FIGURE 1, is the surfacing sheet of kraft paper 18 of ninety pound weight per thousand square eet. I i s This surfacing sheet has printed on it a wood grain design which may for instance be a reproduction of the grain of walnut and be of an appropriate brown color. This printing is covered by a protective coating 20 of extruded polyethylene with a thickness of 0.75 of a mil. I

The three kraft components of the blank are bound together into a generally conventional corrugated paper board by a waterproof adhesive and given a water repellent treatment.

In FIGURE 2 is shown a portion of a beam '22 formed by bending the blank 12 along the scored lines. This shaping may be accomplished by folding the blank around a wooden triangular form.

Through this bending the sections a and a of the blank become the two lower sides of the triangular main body 24 of the beam while sections b and b form the opposite, parallel horizontal shoulders 25 which together constitute the upper side of the main body.

Sections c and c extend upwardly in contiguous relation creating a web 28 by which the beam is suspended. The sections and c are held securely together, as a seam, by a series of staples 30. In this particular embodiment the sides of the triangular body would be approximately one and three eighths inches wide.

In FIGURE 3 is illustrated a portion of an installation of acoustical panels 32 which are principally supported on a series of the beams 22. Each of these beams is suspended from ceiling elements by hangers which may be flat metal straps 34. These are inserted between sections c and c of the web 28 and are fastened thereto by bolts 36 which extend through the sections and through a hole in the lower end of each of the hanger straps. The straps 34 are recommendedly spaced at four foot intervals and may be fastened to ceiling elements such as the joist 40 by nails or screws 42.

A flat sided beam 43, comparable in shape to half of the main beam 22 when split vertically and longitudinally, is used to support the edges of the ceiling panels abutting the walls of the rooms in which the panels are installed. The beam lays flatly against the wall 45 and may be fastened thereto by a staple or nail 44 extending through the upper web portion of the beam. An upwardly facing shoulder or ledge 46 on the beam is adapted to receive the edges of the panels 32.

Between the main beams 22 and between main beams 22 and wall beams 43 of the installation illustrated in FIG- URE 3 extend cross beams 48. These have a main body of triangular cross section of the same dimensions as the body of the main beams. The cross beams 48, as illustrated in FIGURE 4 as well as in FIGURE 3, have an upwardly extending seam flange 50, integrated with staples 52, which projects upwardly between panels. The cross beams are not suspended from hanger straps but instead are supported by the attachment of their end flanges or wings 54 by staples 56 to the webs 28 of the main beams 22, and the webs of the beams 43.

A complementarily shaped cut out portion 58 at the ends of the cross beam '48 fits over the shoulder 25 and against one side of the body of the main beam 22 or the shoulder 46 on the side of beam 43. The cross beams 48 are not necessarily placed vbetween all of the adjacent panels as their function is mainly that of creating a certain architectural effect and accordingly they may be spaced any number of panels apart.

The acoustical panels 32 for an installation such as illustrated in FIGURE 3 may be two by four feet in the planar dimensions, and one and half inches thick. A panel of such thickness provide-s thermal insulation as well as sound absorption. For decorative purposes and also to add some rigidity to the comparatively low density panels, a plastic facing may be adhered somewhat tautly to the exposed surface of the panel. This facing may, if desirable, be imprinted with a wood grain design. A lighter color should afford an attractive contrast to the dark walnut color of the grain imprinted upon the beams.

A beam embodying another form of this invention is presented in the fragmentary installation of FIGURE 5. This beam 62 has a main body member of rectangular section, a shape more closely simulating a conventional wooden ceiling beam or overhead floor joist.

A rather large size of beam such as 62 may have a body four inches wide and five inches high. As shown in FIGURE 5 the beam 62 has an upper web portion or seam 66 integrated by staples 68. Hangers 70 for suspending the beam are secured to the web 66 in the same manner as the hangers 34 are fastened to the web 28 as explained in describing the installation shown in FIGURE 3. Acoustical panels 72 rest on the upper shoulders 64 of the main beam 62.

Wooden inserts 74 fitting tightly within the body of the beam 62 and held thereto by staples 75 maintain the beam in rectangular shape and also provide extra strength.

The decorative cross beams 76 with rectangularly shaped bodies, in this instance, of smaller size than the main beams, may be mounted between the main beams 62 at any desired spacing measured by one or more of the panels 72.

The cross beam 76 has an upper web section 78 to fit between adjoining panels 72, and is held in position through the lodgment of its ends, in U-shaped frames 82 which may be held on the sides of main beams 62 by a suitable adhesive.

In the enlarged view of a frame 82 in FIGURE 6 it may be seen that the flat sided receiving socket portion of the frame is formed by the upper side of the lower cross member 84 and the inner faces of the upright side arms 86. The lettering from a" through m on the sections divided by scoring of the blank 88, shown in FIGURE 7, indicates through the corresponding lettering on the frame 82 how this element is formed by folding the blank. Staples through or adhesive between overlying portions of sections a and m; d and j; and e and k hold the frame in its folded shape.

Instead of by the frames 82 the cross beam 76 may be supported by the main beams through end wings or flanges such as the flanges 54 on cross beams 48 shown in FIG- URES 3 and 4.

If desirable the beam of this invention may take other shapes such as those shown in FIGURES 8 and 9. The beam of FIGURE 8 has a trapezoidal section which would have strength comparable to the beams of FIG- URES 2, 3 and 4 and might be considered to be more decorative in some circumstances.

The arcuate lower portion of the beam 92 shown in FIGURE 9 may be, in some respects, weaker structurally than the previously described beams. However, its rounded contour is adapted to harmonize with a less angular architectural scheme.

From the foregoing description, in conjunction with the accompanying drawings, it may be seen that applicant has provided an acoustical ceiling structure of a particularly novel and attractive arrangement.

The wooden beam effect has an old fashioned, mellow quality contrasting with the rather severe nature of the usual modernistic acoustical panel installation.

The subject structure is particularly adapted to dens, family and recreational rooms now most frequently wood panelled and presenting an easy, hospitable atmosphere compared to that of formality and preciseness quite often found in living and dining rooms.

The basic feature of the invention is considered to reside in providing light weight, simulated wood beam supports for acoustical panels and means on the supports for suspending them from a permanent ceiling. This uniquely gives special decorative emphasis to the acoustical panel supporting means, and creates a contoured ceiling structure quite at variance with the usual planar acoustical panel installation.

While generally horizontal ceiling installations have been disclosed the beams may be angled for a rafter effect.

Since light weight and low cost are most important the hollow beams of this invention are most desirably formed from materials such as corrugated paper board, cardboard, or plastic sheets. The latter, particularly, could also be furnished in bright colors.

Other features of the invention include the novel structures of the cross beams, beams for setting against side walls, and supplemental attachment devices for such means.

I claim:

1. Ceiling structure including a substantially dimensioned hollow beam of folded corrugated paper, adjoining flexible edges of the corrugated paper forming a seam along the medial longitudinal line of the upper side of the beam, the upper side of the beam having flat horizontal areas along opposite sides of the seam, panels with border portions resting on the flat horizontal areas of the beam and supported thereby, spaced beam hangers extending down into the seam between the adjoining flexible edges of the corrugated paper, and means securing the hangers to the beam.

2. Ceiling structure according to claim 1 in which the outer surface of the hollow beam is imprinted with a wood grain design with a protective film thereover of clear resin.

3. Ceiling structure according to claim 1 in which there are shape retaining elements fitted within the beam at spaced intervals longitudinally thereof.

4. Ceiling structure according to claim 1 in which the hollow beam is rectangular in cross section.

5. Ceiling structure according to claim 1 in which the hollow beam is triangular in cross section.

6. Ceiling structure including a substantially dimensioned hollow beam of folded flexible sheet material with its outer surface imprinted with a wood grain, adjoining flexible edges of the sheet material forming a seam along the medial longitudinal line of the upper side of the beam, the upper side of the beam having flat horizontal areas along opposite sides of the seam, panels with border portions resting on the flat horizontal areas of the beam and supported thereby, spaced beam hangers extending down into the seam between the adjoining flexible edges of the sheet material, and means securing the hangers between the flexible edges.

References Cited by the Examiner UNITED STATES PATENTS 1,312,056 8/1919 Shaw 52-86 2,150,344 3/1939 Schilling 52144 2,390,262 12/ 1945 Mazer 52-506 2,816,851 12/1957 Arledter 161-413 X 2,824,342 2/ 1958 Hoyle 52-726 2,990,921 7/1961 Wilde 52-495 3,013,644 12/1961 Smith 52-666 FOREIGN PATENTS 1,035,353 1953 France.

123,374 1919 Great Britain.

FRANK L. ABBOTT, Primary Examiner.

JACOB L. NACKENOFF, Examiner.

J. E. MURTAGH, Assistant Examiner.

Claims (1)

1. CEILING STRUCTURE INCLUDING A SUBSTANTIALLY DIMENSIONED HOLLOW BEAM OF FOLDED CORRUGATED PAPER, ADJOINING FLEXIBLE EDGES OF THE CORRUGATED PAPER FORMING A SEAM ALONG THE MEDIAL LONGITUDINAL LINE OF THE UPPER SIDE OF THE BEAM, THE UPPER SIDE OF THE BEAM HAVING FLAT HORIZONTAL AREAS ALONG OPPOSITE SIDES OF THE SEAM PANELS WITH BORDER PORTIONS RESTING ON THE FLAT HORIZONTAL AREAS OF THE BEAM AND SUPPORTED THEREBY, SPACED BEAM HANGERS EXTENDING DOWN INTO THE SEAM BETWEEN THE ADJOINING FLEXIBLE EDGES OF THE CORRUGATED PAPER, AND MEANS SECURING THE HANGERS TO THE BEAM.

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