US3505771A

US3505771A - Acoustical ceiling

Info

Publication number: US3505771A
Application number: US704890A
Authority: US
Inventors: Walter W Thompson
Original assignee: Individual
Current assignee: Individual
Priority date: 1968-02-12
Filing date: 1968-02-12
Publication date: 1970-04-14
Anticipated expiration: 1987-04-14
Also published as: DE1759796C3; GB1182083A; DE1759796A1; FR1570830A; DE1759796B2

Description

April 14, 1970 w. w. THOMPSON ACOUSTICAL CEILING 3 Sheets-Sheet 1 Filed Feb. 12, 196E FIG.|

0 28 .m 2322 0 6 8 4 6 O 2 8/ 3 2 5G 3 |l O 4E| 4 m m a 2 F .l /h 6 B 7 04 0 2 42 1. 9 8 2 a a 4 6 FIG-4 INV ENT OR WALTER W. THOMPSON April 1970 w. w.- THOMPSON 3,505,771

ACOUSTICAL CEILING 3 Sheets-Sheet 2 Filed Feb. 12. 1968 '[HH- 4 4 f 2 P. .T 4 f 1 O l 4 MW r U L l I] 6 mo 5 4 O H2 6 Q 6 m 2 2 w m m w 6 l INVENTOR WALTER W. THOMPSON BY Mia/Mu with @1 ATTORNEYS April 14, 1970 w. w. THOMPSON ACOUSTICAL CEILING 3 Sheets-Sheet 3 Filed Feb. 12 1968 FIG.9

FIGII INVENTOR WALTER W. THOMPSON ATTORNEYS United States Patent O M 3,505,771 ACOUSTICAL CEILING Walter W. Thompson, P.0. Box 627, Hazlehurst, Ga. 31539 Filed Feb. 12, 1968, Ser. No. 704,890 Int. Cl. E04b /52 US. Cl. 52495 6 Claims ABSTRACT OF THE DISCLOSURE The acoustical ceiling system is made up essentially of rows of acoustical panels and light fixtures. Alternate rows have acoustical panels supported on longitudinal bars extending along the sides thereof. The remaining rows consist alternately of acoustical panels and lighting fixtures. The lighting fixtures are supported by the longitudinal bars. The acoustical panels between the lighting fixtures in one embodiment of the invention are supported entirely by transverse bars extending between the longitudinal bars, and in another embodiment are supported in part by the transverse bars and in part by straps or spring clips extending over the longitudinal bars.

SUMMARY OF THE INVENTION It is a primary object of this invention to provide an improved ceiling system composed of both acoustical panels and lighting fixtures.

Another object of this invention is to provide an acoustical ceiling system wherein the alternate rows of acoustical panels are supported from longitudinal bars extending along the sides thereof, and transverse bars connected to the longitudinal bars provide all or part of the support for the acoustical panels in the remaining rows.

Another object is to provide an acoustical ceiling system wherein lighting fixtures are provided in the remaining rows.

Another object is to provide an acoustical ceiling system wherein each of the remaining rows consists alternately of lighting fixtures and acoustical panels.

Another object is to provide adjustable means for supporting the lighting fixtures directly from the longitudinal bars.

Another object is to provide an acoustical system wherein the acoustical panels are supported independently of the lighting fixtures.

Another object is to provide an improved connection between the transverse bars and the longitudinal bars so that the transverse bars may be twisted to facilitate the removal of the acoustical panels.

Other objects and features of the invention will become apparent as the description proceeds, especially when taken in conjunction with the accompanying drawings, wherein:

FIGURE 1 is a plan view of an acoustical ceiling system seen from below and constructed in accordance with my invention.

FIGURE 2 is a sectional view taken on the line 22 in FIGURE 1.

FIGURE 3 is a sectional view taken on the line 3-3 in FIGURE 1.

FIGURE 4 is a sectional view taken on the line 44 in FIGURE 1.

FIGURE 5 is a sectional view taken on the line 5--5 in FIGURE 1.

FIGURE 5A is a fragmentary perspective view of a longitudinal bar and a transverse bar prior to assembly.

FIGURE 6 is similar to FIGURE 5 but shows a modification.

FIGURE 7 is a sectional view taken on the line 7-7 in FIGURE 6.

3,505,771 Patented Apr. 14, 1970 FIGURE 8 is like FIGURE 7 but shows a further modification.

FIGURE 9 is like FIGURE 4 but shows still another modification.

FIGURE 10 is a sectional view taken on the line 1010 in FIGURE 9 FIGURE 11 is a view similar to FIGURE 6 showing a further modification.

Referring now more particularly to the drawings and especially to FIGURES 1 to 5A, the ceiling structure is generally indicated by the reference numeral 10 and is composed of individual separable

rectan ular panels

12 and 14, and lighting fixtures 16. The panels 12 are arranged in alternate rows A, and the panels 14 and lighting fixtures 16 are arranged in the remaining rows B. The bottom surfaces of all of the panels and lighting fixtures are in a common horizontal plane.

The panels 12 are identical to one another and in the form shown each may have a sheet metal front facing 18 and a sheet metal rear facing 20 which is parallel to and spaced above the front facing. The front facing may, if desired, be and preferably is perforated. While the interior of the panel may vary, a honeycomb structure 22 is shown sandwiched between the facings. The honeycomb may be formed of a cardboard material and together with the

facings

18 and 20 provides a strong composite panel structure which resists bending or twisting. A heat insulation and sound absorbing material 24 which may be formed of glass, wool or wood fibers, may fill the cells of the honeycomb 22.

The sides of the front facing 18 are turned upwardly to provide side walls 26. The side walls 26 are disposed at right angles to the front facing and terminate in outwardly extending and return-bent flanges 28. The sides of the rear facing 20 are turned downwardly to provide side walls 30. The side walls 30 extend at right angles to the rear facing and are respectively disposed in the same plane as the side walls 26. The side walls 30 terminate in horizontally outwardly extending flanges 32 which are clamped within the return-bent flanges 28 to seal the side margins of the panel and to provide a reinforced flange designated 34 (consisting of the flanges 28 and 32) about midway between the front and rear facings.

The ends of the panels 12 are clearly shown in FIG- URE 4. As there seen, the rear facing 20 has its ends turned downwardly at a right angle to provide

end walls

34 and 35 extending to the front facing of the panel. The end wall 34 and the front facing are seen to have end extensions in surface-to-surface relation which extend substantially in the plane of the front facing and then turn up forming a flange 36 parallel to end wall 34. One of the extensions maybe return-bent over the other at the upper edge of flange 36. The end wall 35 and the front facing have extensions in surface-to-surface relation which extend substantially in the plane of the front facing and then extend in the shape of an inverted U to form a hook 37. One of the extensions forming the hook may be returnbent over the other at the extremity of the hook 37. The panels 12 are oriented the same way so that when installed in the rows A the hooks 37 of each panel extend over and hook onto the flanges 36 of the adjacent panel.

The panels 14 are identical to one another and each may have a sheet metal front facing 40 and a sheet metal rear facing 42 which is parallel to and spaced above the front facing. The front facing may be and preferably is perforated. A honeycomb structure 43 may be sandwiched between the facings. The honeycomb structure may be formed of the same material as that employed in panels 112, and the cells thereof are preferably filled with a heat insulating and sound absorbing material 44 like that employed in the panels 12.

The rear facing 42 has its side edges turned downwardly at a right angle to provide side walls 46 which extend to the front panel 40. The front panel 40 and side walls 46 have extensions 48 disposed in surface-to-surface relation which project laterally outwardly substantially in the plane of the front facing and then turn up at a right angle to provide flange 50. One of the extensions may be return-bent over the other at the upper edge of the flange 50. The end construction of panels 14 is similar to the side construction of panels 12. Thus the front facing 40 has its end edges turned upwardly at a right angle to provide end walls 52, and the rear facing 42 has its end edges turned downwardly at a right angle to provide end walls 54. The

end walls

52 and 54 are disposed respectively in the same planes, and these end walls terminate about midway of the thickness of the panels and have extensions turned horizontally outward in surface-to-surface

relation providing flanges

56 and 58, the flange 58 being returnbent over the flange 56 to provide a rigid sealed flange 60 composed of the

individual flange elements

56 and 58.

The lighting fixtures 16 contain suitable lighting devices within houses 64 and across their bottom faces are closed by a transparent or translucent panel 66 having upturned flanges 68 along its four sides. The panel 66 is of course rectangular. Suitable brackets 70 are provided on each housing 64 which are shown in FIGURE 3 in their extended positions but which are adjustable and may be withdrawn inwardly with respect to the housing. For example, the brackets 70 may be hinged on pins 71 so that they may be swung inwardly flat against the wall of the housing or outward as shown to an extended operative position. Any suitable adjustable mounting for such brackets 70 may be employed.

The acoustical ceiling system includes a plurality of horizontal laterally spaced, parallel, elongated longitudinally extending bars 80. The longitudinal bars 80 are of identical construction. As shown in FIGURES 2 and 3, the elongated bars 80, while equally spaced, are arranged in pairs with the bars of each pair having their lower horizontal flanges 82 turned toward one another.

Each bar 80 is of the cross section shown in FIGURES 2 and 3, having a flat vertical main section 84 provided with an open return-bent bead or flange 86 along its upper edge. The flange 82 extends laterally at right angles to the main section 84 of the bar and is return-bent upon itself as shown in order to strengthen the same. The bars 80 are suspended from a permanent overhead ceiling structure by means of hangers 88 in the form of cords or wires which are looped through holes 90 in the bars. The bars 80 are thus supported at suitable intervals along their length by the hangers 88 in parallel relation to one another so that their flanges 82 occupy the same horizontal plane.

The spacing between adjacent longitudinal bars 80 may, if desired, be maintained by suitable cross members 92. These cross members may be of V shape as shown, having notches 94 on their undersides into which the beads 86 along the upper edges of the bars 80 fit. The cross members 92 may merely rest upon adjacent bars in the manner shown to maintain a proper spacing therebetween.

The panels 12 in the rows A are supported from the bars 80 along the two sides thereof by having their side flanges 34 rest upon the flanges 82 of the bars 80. One end of each panel 12 in the row has its hook 37 engaged over the flange 36 on the end of the adjacent panel.

In the rows B, the lighting fixtures are supported by their brackets 70 extending over and resting upon the beads 86 of the longitudinal bars 80. The panels 14 between lighting fixtures 64 are supported by transverse bars 100. The cross section of the transverse bars 100 is substantially the same as the longitudinal bars, having a main flat vertical section 102 with an open return-bent flange or head 104 along the upper edge and a lower lateral right angle flange 106 return-bent upon itself. These transverse bars 100 are disposed at longitudinally spaced intervals in the rows B and extend at right angles to the longitudinal bars 80. The end flanges 34 of the panels 14 rest and are supported upon the flanges 106 of the transverse bars. It will be noted that the transverse bars 100 are arranged in pairs so that the flanges 106 of each pair of transverse bars extend toward one another in order to support a panel. 14.

The connection between the transverse bars 100 and longitudinal bars 80 is clearly shown in FIGURES 2, 5 and 5A. As there shown, the ends of the transverse bars have extensions or tabs 110 disposed in the plane of the flat vertical section 102 and provided with notches 112 along the bottom edges thereof. These extensions are formed to fit within special slots 114 provided in the longitudinal bars 80. Each slot 114 has an upper portion provided with an upright wall 116 on one side and an upwardly flaring wall 118 on the opposite side, and a lower portion. provided with an upright wall 120 on the side corresponding to the flaring wall 118 and a downwardly flaring wall 122 on the opposite side. The flaring

walls

118 and 122 are substantially parallel. The bottom portion of the slot is closed by a horizontal wall 124 connected to the wall 120 by a notch 126. When a transverse bar 100 is supported in vertical, upright or operative position, its tabs 110 project into aligned slots 114 in adjacent longitudinal bars 80 with one side of the main vertical section 102 thereof against the upright wall 116 and the opposite side thereof against the upright wall 120. At this time the notches 112 of the tabs engage in the notches 126 of the slots to thereby lock the transverse bars in vertically upright position.

It will be noted in FIGURE 5 that the slots 114 are alternately slanted one way and the other, or may be considered to be arranged in pairs corresponding to the pairs of transverse bars. The oppositely slanting slots 114 are mirror images of one another.

The system thus described requires that one or more of the panels 12 be removed first before the lighting fixtures 16 can be removed or before the panels 14 can be removed. A panel 12 is removed from the system by elevating the end 35 having the hook 37, then tilting and twisting the panel to disengage the side flanges 34 of the panel from the supporting flanges 82 of the longitudinal bars 80, andthen lowering the panel 12 from the ceiling system. Thereafter a lighting fixture 16 can be removed by reaching into the space left vacant by the panel 12 to withdraw or retract the brackets from supporting engagement on the longitudinal bars and lowering the lighting fixture 16 from the ceiling system. Then the adjacent panel or panels 14 may be removed by lifting one or both of the transverse bars supporting each panel 14 to be removed to disengage their tabs from the notches 126 of the slots and partially rotating the transverse bars 100 to withdraw the flanges 106 of the transverse bars from supporting relation to the end flanges 34 of the panels 14 so that the panels may be lowered from the ceiling system. The tabs of the transverse bars 100 are not removed from slots 114 by this rotation, but are merely turned into contact with

slot walls

118 and 120.

FIGURES 6 and 7 show a modification of the invention wherein, the panels 14 are replaced by panels 14:; which diifer from the panels 14 in that one end only of the panel 14a has the end flange construction 60. The other end of the panel 14a has merely a flush construc tion in which the front and rear facings are turned at right angles toward one another in substantially the same plane and overlapped to provide the substantially flush condition shown at in FIGURE 6. The end of each panel 14a which has the flush construction is supported in the system by straps or hangers 200. A snap fastener or button 202 extends through a hole in the lower end of the strap or hanger 200 and through a hole in the side of the panel 14ato provide a releasable connection between the panel and the strap. The fastener may have an enlarged head as shown engaging the surface of the strap, and legs extending through the opening in the strap and through an opening in the side of the panel. Any suitable type fastener may be employed but preferably one of the type shown and described in my co-pending application Ser. No. 471,263 filed July 12, 1965, now Patent No. 3,400,506 in which the' legs are flexible and enlarged on their terminal ends so as to releasably be retained in the panel. The upper end of the strap is return-bent in an open U-shape as shown at 205 to engage over the bead 86 along the upper edge of one of the longitudinal bars 80. It will be understood that the opposite side of the panel 140 is similarly supported by a strap 200 buttoned or fastened to the side wall of the panel.

' The opposite end of the panel 14a is supported exactly the same as in the embodiment shown in FIGURES l-5, that is with its end flange 60 resting upon the flange 106 at the lower end of the transverse bar 100.

It will be apparent that these straps 200 can be reached when one or more of the panels 12 have been removed and hence the panels 14a can be removed from the system without requiring that a light fixture 16 be removed. The straps 200 are of course flexible so that they can be engaged over or released from the beads 86.

FIGURE 8 discloses a further modification in which the up er end of the strap 200a is formed with a right angle part 210 and an upwardly extending inclined or cam part 212. It will be understood that the other strap employed in the FIGURE 8 construction for the support of the opposite side of the panel 14w will be of the same construction as the strap 200a. The straps 200a will be of a flexible resilient material so that the panel 14w may be installed by being moved upwardly into the ceiling assembly and causing the cam parts 212 to deflect the straps inward as they move upwardly past the beads 86 after which the straps will snap outward to the supporting position shown in FIGURE 8 in which the right angle part 210 engages and is supported upon the bead 86. To remove the panel in FIGURE 8, a panel or panels 12 will first be removed, whereupon straps 2001: can be reached and removed by flexing from engagement with beads 86 without the need to remove a lighting fixture.

In neither the FIGURE 7 nor the FIGURE 8 embodiment is it necessary to tilt a transverse bar 100 to remove the panel 14a. Therefore, the special slots 114 are not needed for these embodiments, although they may be employed. Any other suitable connection between the transverse bars and longitudinal bars may be used.

FIGURES 9 and 10 show a modification of the invention shown in FIGURES 1-5 in which the V-shaped spacers 92 are replaced by transverse members 300 spaced apart at 6' intervals, for example. Each transverse member 300 has a main flat vertical section 302 with an open return-bent flange or bead 304 along the upper edge and a right angle strengthening flange 306 along the lower edge. The connection between the transverse members 300 and the longitudinal bars 80 is clearly shown in FIGURES 9 and 10. The ends of each transverse member 300 have extensions or tabs 310 disposed in the plane of the flat vertical section 302 and provided with notches 312 along the upper and lower edges. These extensions or tabs are identical and are formed to fit within special slots 314 provided in the longitudinal bars 80. One of the transverse bars 300 is omitted so that the slot outline may be seen more clearly. The slots are identical and each has an upper portion provided with an upright wall 316 on one side and an upwardly flaring wall 318 on the opposite side, and a lower portion provided with an upright wall 320 on the side corresponding to the flaring wall 318 and a downwardly flaring wall 322 on the opposite side. The flaring

walls

318 and 322 are substantially parallel. The bottom portion of the slot is closed by a horizontal wall 324 connected to the wall 322 by a notch 326. The top portion of the slot is closed by a horizontal wall 328 connected to the wall 318 by a notch 330.

When a transverse member 300 is supported in up right or operative position, its tabs 310 project into aligned slots 314 in adjacent longitudinal bars with one side of the main vertical section 302 thereof against the upright wall 316 and the opposite side thereof against the upright wall 320. At this time the notches 312 of the tabs engage the top and bottom

horizontal walls

324 and 328 of the slots to thereby lock the transverse members against pulling out. To remove the transverse members 300, they are rotated to an angular position engaging the flaring

walls

318 and 322 and

notches

326 and 330 and then withdrawn.

FIGURE 11 shows a modification of the invention in FIGURE 6 in which the panels 14b replace the panels 14a and are like the panels 14a except that both ends are of the flush construction shown in FIGURE 6. Also, both ends of the panels 14b are suspended from the longitudinal bar 80 by the two resilient straps 200a shown in FIGURE 8. Two straps 200a opposite the two shown also support the opposite side of the panels adjacent the ends from the other longitudinal bar 80. The straps 200a are buttoned to the sides of the panels in the same manner as in FIGURE 8, but by two fasteners 202 instead of one. It will be understood that the other form of straps shown in FIGURES 6 and 7 at 200 may be employed in place of straps 202. In this embodiment of the invention, since both ends of the panels 14b are suspended by straps directly from the longitudinal bars 80, the transverse bars are not required. However, the V-type spacers 92 are provided both in rows A and rows B to maintain a predetermined spacing between the longitudinal bars 80. It will be understood of course that the transverse members 300 may be employed in place of the V-shaped spacers 92.

What I claim as my invention is:

1. An acoustical ceiling system comprising a plurality of laterally spaced, parallel, longitudinal bars, acoustical panels in alternate spaces between bars, said bars having flanges engaging the opposite sides of said panels to provide the sole support therefor, acoustical panels in the remaining spaces between bars, and a plurality of 1011- gitudinally spaced, transverse bars in said remaining spaces having flanges engaging the opposite ends of said second-mentioned panels to provide the sole support therefor.

2. The acoustical ceiling system defined in claim 1, wherein said transverse bars are arranged in pairs with the flanges of each pair extending toward one another, one of said second-mentioned panels being disposed between each pair of transverse bars, said second-mentioned panels having end flanges respectively supported upon the flanges of said transverse bars.

3. The system defined in claim 2, wherein lighting fixtures supported by said longitudinal bars are provided between said second-mentioned acoustical panels in each of said remaining rows.

4. The acoustical ceiling system defined in claim 3, wherein said transverse bars have end tabs engaging in slots in said longitudinal bars, each slot having an upper portion provided with an upright wall on one side and an upwardly flaring wall on the opposite side and also having a lower portion provided with an upright wall on said opposite side and a downwardly flaring wall on said one side, said upright walls locating said transverse bars in upright position, each slot having a locking recess at the bottom in which a hook portion of the tab of the associated transverse bar is engageable to lock the same in upright position, said flaring walls permitting said transverse bars to be partially rotated from upright position when said tabs are raised to release said hook portions from said locking recesses and thereby withdrawn from supporting relation to said second-mentioned panels so that the latter may be removed from the system.

5'. An acoustical ceiling system comprising a plurality of laterally spaced, parallel, longitudinal bars, acoustical panels in alternate spaces between bars, said bars having flanges engaging the opposite sides of said panels to provide the sole support therefor, acoustical panels in the remaining spaces between bars, and a plurality of support members supported by said longitudinal bars in said remaining spaces and engaging said second-mentioned panels adjacent the ends thereof to provide the sole support therefor, said support members including hanger straps, said hanger straps being flexibly resilient and each having a catch portion and an inclined camming portion extending upwardly therefrom to snap over and engage the upper edge of a longitudinal bar upon upward movement of said second-mentioned panels into assembly in the ceiling system.

6. An acoustical ceiling system comprising a plurality of laterally spaced parallel, longitudinal bars, acoustical panels in alternate spaces between bars, said bars having flanges engaging the opposite sides of said panels to provide the sole support therefor, acoustical panels in the remaining spaces between bars, a plurality of longitudinally spaced hanger straps suspended from said longitudinal bars in said remaining spaces and having means engaging said second-mentioned panels adjacent one end thereof, and a plurality of longitudinally spaced, transverse bars in said remaining spaces having flanges engaging the opposite ends of said second-mentioned panels, said hanger straps and transverse bars together providing the sole support for said second-mentioned panels.

References Cited UNITED STATES PATENTS 2,071,865 2/1937 Parsons 52488 2,882,558 4/1959 Jacobson 52488 2,894,291 7/1959 Sorenson 52488 X 3,087,205 4/ 1963 Mancini 52475 3,164,230 1/1965 Adams 52498 X 1,997,596 4/1935 Paley 52145 2,334,484 11/1943 Dunbar. 2,946,414 7/1960 Gordon 52495 X 2,994,113 8/1961 Dail 52497 X 3,153,304 10/1964 Evangelista 52496 X 3,155,324 11/1964 Chen 240-9 3,163,961 1/1965 Kemp 52485 X 3,327,444 6/1967 Downing 52496 FOREIGN PATENTS 597,413 1948 Great Britain. 355,276 1961 Switzerland.

JOHN E. MURTAGH, Primary Examiner US. Cl. X.R. 5228, 484, 497