SUSPENDED CEILING SYSTEMS HAVING A PLURALITY OF L-SHAPED PANELS

Description

RELATED APPLICATIONS

This application claims the benefit of priority as a Non-Provisional application to U.S. Provisional Patent Application No. 63/638,966 filed on, Apr. 26, 2024, the contents of which are incorporated in this application by reference.

TECHNICAL FIELD

The present invention relates to building panel systems. Particular embodiments of the invention relate to ceiling systems having removable panels. The incorporations of main beams, cross teas with different clip configurations and at least one specific bracket results in ceiling systems having unique grid designs for supporting an unconventional panel having a plurality of different shapes, colors, and/or textures.

BACKGROUND OF THE INVENTION

Suspended ceilings in rooms are common. Suspended ceilings having metal beams or runners forming a grid system adapted to receive lay in ceiling tiles that are supported by the grid system. These grid systems can have a plurality of metal or plastic main beams and a plurality of metal or plastic cross members that span the gaps between the main beams.

A problem exists in that these grid systems with lay in ceiling tiles can be restrictive in that the possible visual appearances that can be created are limited. Accordingly, embodiments of the invention provide ceiling systems that allow more creativity and less restriction due to the use of multiple different tiles and the use of grid systems that permit the use of multiple different tiles.

BRIEF SUMMARY OF THE INVENTION

To incorporate such ornamental panels and create unique, suspended ceilings, a ceiling system with parallel main beams and cross tees connects to right angle brackets is disclosed.

The ceiling system forms a grid for use in a building space having a plurality of walls. The ceiling system may be attached to the walls or be a floating system (i.e., not attached to any walls). The ceiling system comprises at least two main beams. At least two cross tees and one bracket traverses the space between the main beams to form unique shapes into which unique ceiling tiles may be laid. Specifically, a first cross tee is attached to: (1) the first main beam or a first cross-tee-spanning-a-first-and-second-main-beam at one end of the first cross tee and (2) a first bracket at the opposite end of the first cross tee. A second cross tee is attached to: (1) the first bracket at one end of the second cross tee and optionally (2) a second cross-tee-spanning-a-first-and-second-main-beam or a first main beam or a second bracket opposite end of the second cross tee. Optionally, a third cross tee may be attached to: (1) the second bracket at one end of the third cross tee and (2) the second main beam or a second cross-tee-spanning-a-first-and-second-main-beam at the opposite end of the third cross tee. In addition, both the first bracket and optional second bracket have the same design including: (1) a first section comprising: a first vertical wall extending upward from a set a bottom flange, and (2) a second section comprising a second vertical wall extending upward from the bottom flange. The first section and second section are connected to each other at approximately a ninety-degree angle.

In certain embodiments, the first main beam and second main beam are parallel. In other embodiments, the first main beam and second main beam are perpendicular. In such embodiments, the grid takes on a substantially L-shape, U-shape, or Z-shape while the grid forms a substantially L-shaped or U-shaped opening adapted to receive at least one laid in ceiling tile.

In certain embodiments, the ceiling system further includes at least one laid in ceiling tile. The ceiling system may also include two or more laid in ceiling tiles where one ceiling tile is a substantially L-shaped or U-shaped ceiling tile and another ceiling tile takes on a substantially L-shape or square or rectangular shape. For example, if the first tile is substantially L-shaped, the second tile may be substantially L-shaped or square or rectangular. Furthermore, if the first tile is substantially U-shaped, the second tile may be square or rectangular.

In certain embodiments, the flange of the brackets may include a step and may also extend past the terminal end of either the first section, second section, or both.

It is to be understood that both the foregoing general description and the following detailed description are exemplary, but are not restrictive, of the invention.

BRIEF DESCRIPTION OF THE DRAWING

The invention is best understood from the following detailed description when read in connection with the accompanying drawing. It is emphasized that, according to common practice, the various features of the drawing are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawing are the following figures:

FIG. 1 is a perspective view of one embodiment of a ceiling system.

FIG. 2A is a top right perspective view of a cross tee for the ceiling system shown in FIG. 1.

FIG. 2B is a bottom right perspective view of the cross tee for the ceiling system shown in FIG. 1.

FIG. 3A is a top left perspective view of a cross tee for the ceiling system shown in FIG. 1.

FIG. 3B is a bottom left perspective view of the cross tee for the ceiling system shown in FIG. 1.

FIG. 4A is a top left perspective view of a bracket for the ceiling system shown in FIG. 1.

FIG. 4B is a top right perspective view of the bracket for the ceiling system shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The features and benefits of the disclosed brackets, clips, beams, and ceiling system are illustrated and described by reference to exemplary embodiments. The disclosure also includes the drawing, in which like reference numbers refer to like elements throughout the various figures that comprise the drawing. This description of exemplary embodiments is intended to be read in connection with the accompanying drawing, which is to be considered part of the entire written description. Accordingly, the disclosure expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combinations of features that may exist alone or in other combinations of features.

In the description of embodiments, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top,” and “bottom” as well as derivatives of those terms (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be construed or operated in a particular orientation. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar terms refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both moveable or rigid attachments or relationships, unless expressly described otherwise.

Ceiling System

FIG. 1 depicts an exemplary embodiment of a ceiling system 100 according to the present disclosure. The ceiling system 100 depicted includes at least two main beams 200 running substantially parallel to each other. Cross tees 300 run between the main beams 200. The cross tees 300 connect to other cross tees 300 with brackets 400 having clips 500. Indeed, each cross tee 300 includes at least one clip 500 adapted to engage with the same type of clip 500 attached to the bracket 400. By having cross tees 300 attached to brackets 400 between main beams 200 an ornamental ceiling design may be created. Such ornamental designs may result in grid adapted to receive laid in panels 600 with unique shapes. For example, at least two cross tees 300 connected to at least one bracket 400 may form grid adapted to accept panels having a substantially L-shape (three cross tees and two brackets), an L-shape and a square or rectangular shape (two cross tees and one bracket), or an U-shape or square or rectangular shape (three cross tees and two brackets).

Beams & Tees

As depicted in FIGS. 1-3, the ceiling system 100 includes both main beams 200 and intersecting cross tees 300. Regardless of type, beams 200 and tees 300 are formed generally of flat sheet metal folded into an inverted T cross section having a web 210 and 310, a bulb 220 and 320 at the top of the web 210 and 310, and a horizontal flange 230 and 330 extending in both directions from the bottom of the web 210 and 310. The web 210 and 310 is formed of two adjacent layers typically stitched 240 together by punching a portion of one layer through a portion of the second layer surface creating an indentation in the first layer and a bump in the second layer surface. In some instances, the beams 200 and tees 300 are not folded metal but instead are made of extruded material, such as metal (e.g., aluminum) or polymers.

The main beams 200 are typically suspended from a structural ceiling by wires. The main beams 200, which run parallel to one another, are generally spaced 24 inches, 36 inches, or 48 inches (61 cm, 91 cm, or 122 cm) apart. A straight, finished main beam may continuously emerge from a roll-forming operation, and then be cut, on the run, into suitable lengths of, for instance, 12 feet (366 cm).

Cross tees 300 are connected to the main beams 200 through slots in the main beams 200. Such connections form corners. In such a configuration, the cross tees 300 are typically supported by the main beams 200. Cross tees 300 are manufactured in a manner like main beams 200 and cross tees 300 and may be cut into lengths of as short as 4 inches (10.2 cm). In other embodiments, beams 200 and tees 300 may be cut into lengths of 2, 3, or 4 feet (61 cm, 91 cm, or 122 cm). Cross tees 300 are also connected to brackets 400 by clips 560. When cross tees 300 are connected to main beams 200 and brackets 400, a ceiling system with a grid adapted to receive laid-in panels is formed.

Bracket

At least two cross tees 300 are connected to at least one brackets 400 to form the unique grid design. FIGS. 4A and 4B depict an exemplary embodiment of the brackets 400 according to the present disclosure. The bracket 400 includes a first section 410 comprising: a first vertical wall 412 extending upward from the approximate center of bottom flanges 414. The first section 410 is connected to a second section 420 at approximately a ninety-degree angle, plus or minus 0.75 degrees.

The second section 420 comprising: a second vertical wall 422 extending upward from the approximate center of the bottom flanges 414.

The bottom flanges 414 commence at the bottom of the first vertical wall 412 and second vertical wall 422 and extend substantially perpendicularly out in opposite directions from the first and second vertical walls 412 and 422.

In one embodiment, there is a cut out 460 where the first vertical wall 412 connects to the second vertical wall 422. The cutout 460 may take on any shape, such as a circle. In certain embodiments, the cutout 460 may be located closer to the top edge of the vertical walls 412, 422 than the bottom flange 414.

In certain embodiments, the cross tees 300 are taller than the brackets 400. In such an embodiment, the top of the bracket 400 may be just above the bottom of the bulb 320 of the cross tee 300. Such embodiments may assist in the stability of the connection (the top of the bracket can contact the bulb of the grid to limit rotation).

Bottom Flanges

As outlined above, the bottom of the bracket 400 includes the bottom flange 414 that extends substantially perpendicularly out in both directions from the first and second vertical walls 412 and 422. In one embodiment, the flange 414 may extend past a terminal end 416 of the first vertical wall 410. In another embodiment, the flange 414 may extend past a terminal end 426 of the second vertical wall 420.

The flange 414 may have many shapes. For example, the flange 414 may be V-shaped. In another embodiment, a portion of the flange 414 extending from the first vertical wall 410 may contact a portion of the flange 414 extending from the second vertical wall 420 to form a triangular-shaped flange 414. In a still further embodiment, the top and bottom of the flange 414 may be connected by a straight or curved element. In another non-limiting embodiment, the flange 414 may include a face to match the associated grid type (e.g., slotted, textured, or dimensional). The bottom of the flange 414 may also be textured.

The flange 414 may include a step resulting in a portion of the flange 414 closest to the first or second vertical wall 410 and 420 residing in a first plane and the remaining portion of the flange 414 residing in a second plane. In such embodiments, the height and length of the step may be about the same as the height and length of the beam flange 230 and 330. In such a design, the section of the flange 414 comprising the step may rest on the top of the beam flange 230 and 330 with the unsupported portion of the flange 414 residing in substantially the same plane as the beam flange 230 and 330.

Clip

The first and second vertical walls 412 and 422 each include a bracket clip 560 attached to the edge opposite the cutout 460. Two bracket clips 560, each identical to the other, are used to form a cross tee-bracket connection as seen in FIG. 1. Each bracket clip 560 is roughly rectangular and is formed, by cutting or stamping, from relatively hard material, such as steel, having spring properties. Punched holes 510 and 520, are above one another, and are formed in the approximate center of the bracket clip 560 as seen in FIGS. 4A and 4B. A third hole, 530, forming a triangle with the first two, is formed to the rear of the clip, closer to the vertical walls 412 and 422.

In certain embodiments, flanges are formed at the top and bottom edges of the rear of the bracket clip 500, to form a channel. Such flanges may be angled outwardly from the face of the clip opposite the vertical walls 412 and 422.

A tongue 540 extends in a direction towards the front of the bracket clip 560 away from the bracket 400. In certain embodiments, the grid web 210 has an offset section or pan formed in the end of the beam 200 and 300. This pan, which may be rectangular and of a size that slightly exceeds the rectangular dimension of the channel of the clip 560. Such an embodiment is adapted to permit the channel of bracket clip 560 to nest in the pan and restrain movement in the plane of the web. In such embodiments, the pan is pressed to a depth depending on the thickness of the bracket clip 500. Specifically, when the bracket clip 560 is attached to the web 210 in the depressed pan by fasteners, such as flat head rivets past through the pre-punched holes 510, 520, and 530 in the pan, the lateral outward face of the bracket clip 560 will lie in the vertical plane that extends between the layers in the web 210, which is the vertical center plane of the web 210.

The beam web 210 and 310 also has a corresponding beam clip 500. The beam clip 500 includes a terminal edge 595 defined as leading end of the beam clip 500. The beam clip 500 is located between the bulb 220 320 and flange 230 330 of the beam 200 300. The top 580 of the beam clip 500 includes a triangular portion 585. The top 580 of the beam clip 500 optionally includes an outwardly disposed flange. The bottom of the beam clip 500 includes a stop 590.

The beam clip 500 include a fingernail 570 closer to the terminal edge 595 than an aperture 572. The fingernail 570 projecting outward from the surface of the beam clip 500 in a direction towards the beam 200 300. The aperture 572 is adapted to engage with a fingernail 570 of another beam clip 500.

The beam web 210 and 310 also has a cutout 212 and 312 as seen for instance in FIG. 1. This cutout 212 and 312 receives a corresponding terminal edge 595 from a clip 500 560 in the form of a terminal edge 595 projecting through the cutout 212 312. The clip 500 560 nests in the slot cutout 212 of the web 210 and serves to secure the clip 500 560 to the web 212. Furthermore, the clip 500 560 may be secured to the web 212 312 with fastener such as rivets.

In certain embodiments of the bracket clip 560, forward of the stem 550, the projection extends in a form of an extended circular portion that creates a cap 552 in a modified mushroom shape, with the stem 550 extending horizontally when the clip 560 is in place in the ceiling, while the cap 552 of the mushroom shape extends vertically providing a horizontal stop.

In certain embodiments, there may be a cutout at the forward part of cap 552, and a pressed-out detent projecting from the bracket clip 560 beyond the laterally outward face of the bracket clip 560 at the front of the cap 550 adjacent to the cutout. In such embodiments, the detent may have a rearward facing pointed edge.

In certain embodiments, the two flanges at the top and bottom of the clip 500 560 are angled outward from the lateral outward face of the clip 500 560 to form a rear channel. The flanges extend along the rear channel of the clip 500 560 on the part that lies abutting the web 210 310.

A spring pocket 555 is formed on the bracket clip 560, which faces forward and is angled away from the lateral outward face. The rearward part of the pocket has a portion which folds back toward the lateral outward face. The pocket 555 is joined to the outward face of the clip at a fold line. The entire pocket is stamped from the flat bracket clip 560, leaving a cutout portion having a rearward pointing arcuate edge.

A clip 500 560 is fastened to each end of a beam 200 300 or each section 410 420 of a bracket 400. The clips 500 560 are engaged by forcing one clip 500 560 longitudinally into another 500′ 560′. In certain embodiments, the tongue of a bracket clip 560 engages the pocket 560 of another bracket clip 560 as seen in FIG. 1. This will bring the lateral outward faces and of the bracket clips 560 together. The tongue of each bracket clip 560 will be centered and guided within the rearward portion of the other bracket clip by the flanges at the top and bottom of the bracket clip 560.

Detents on each bracket clip 560 will initially ride within the depressed of stems 550, which will permit the faces to be in contact with one another. As each clip is brought forward with respect to the other, the lateral outward faces of the clips 560 will be forced slightly apart as the detents', permitting each clip face to override any portions of the fasteners connecting the bracket clip 560 to the bracket 400 and beams 200 300.

In certain embodiments, as the clips 500 560 advance toward one another, the clips 500 560 continue to be guided by the upper and lower flanges on each clip. In such embodiments the clips 500 560—may finally lock with one another such as when a detent enters a cutout, at which time the spring pocket 555 of each clip will bring the faces back in abutment against one another.

Panels

Various type of lay in panels can be used with the grid system. For example, acoustic tiles may be used. In the case of acoustical tiles, the tiles may comprise fiberglass, mineral wool (such as rock wool, slag wool, or a combination thereof), synthetic polymers (such as melamine foam, polyurethane foam, or a combination thereof), mineral cotton, silicate cotton, gypsum, or combinations thereof. In some embodiments, the tile provides a sound attenuation function and preferred materials for providing the sound attenuation function include mineral wool.

Acoustic ceiling panels exhibit certain acoustical performance properties. Specifically, the American Society for Testing and Materials (ASTM) has developed test method E1414 to standardize the measurement of airborne sound attenuation between room environments 3 sharing a common plenary space. The rating derived from this measurement standard is known as the Ceiling Attenuation Class (CAC). Ceiling materials and systems having higher CAC values have a greater ability to reduce sound transmission through a plenary space—i.e. sound attenuation function. In certain embodiments, the lay in tiles incorporated into the ceiling system 100 provide a CAC (Ceiling Attenuation Class) rating of at least 35, preferably at least 40. CAC is further described below.

Another important characteristic for acoustic ceiling panel materials is the ability to reduce the amount of reflected sound in a room. One measurement of this ability is the Noise Reduction Coefficient (NRC) rating as described in ASTM test method C423. This rating is the average of sound absorption coefficients at four ⅓ octave bands (250, 500, 1000, and 2000 Hz), where, for example, a system having an NRC of 0.90 has about 90% of the absorbing ability of an ideal absorber. A higher NRC value indicates that the material provides better sound absorption and reduced sound reflection-sound absorption function.

Acoustic ceiling panels can have different constructions. In some cases, the body may be porous, thereby allowing airflow through the body between an upper surface and a lower surface. The body may be comprised of a binder and fibers. In some embodiments, the body may further comprise a filler and/or additive.

Non-limiting examples of binder may include a starch-based polymer, polyvinyl alcohol (PVOH), a latex, polysaccharide polymers, cellulosic polymers, protein solution polymers, an acrylic polymer, polymaleic anhydride, epoxy resins, or a combination of two or more thereof.

The binder may be present in an amount ranging from about 1 wt. % to about 25 wt. % based on the total dry weight of the body-including all values and sub-ranges there-between. The phrase “dry weight” refers to the weight of a referenced component without the weight of any carrier. Thus, when calculating the weight percentages of components in the dry-state, the calculation should be based solely on the solid components (e.g., binder, filler, hydrophobic component, fibers, etc.) and should exclude any amount of residual carrier (e.g., water, VOC solvent) that may still be present from a wet-state, which will be discussed further herein. According to the present invention, the phrase “dry-state” may also be used to indicate a component that is substantially free of a carrier, as compared to the term “wet-state,” which refers to that component still containing various amounts of carrier.

Non-limiting examples of filler may include powders of calcium carbonate, including limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, perlite, polymers, gypsum, wollastonite, expanded-perlite, calcite, aluminum trihydrate, pigments, zinc oxide, or zinc sulfate. The filler may be present in an amount ranging from about 25 wt. % to about 99 wt. % based on the total dry weight of the body-including all values and sub-ranges there-between.

Non-limiting examples of additives include defoamers, wetting agents, biocides, dispersing agents, flame retardants, and the like. The additive may be present in an amount ranging from about 0.01 wt. % to about 30 wt. % based on the total dry weight of the body-including all values and sub-ranges there-between.

The fibers may be organic fibers, inorganic fibers, or a blend thereof. Non-limiting examples of inorganic fibers mineral wool (also referred to as slag wool), rock wool, stone wool, and glass fibers. Non-limiting examples of organic fiber include fiberglass, cellulosic fibers (e.g. paper fiber-such as newspaper, hemp fiber, jute fiber, flax fiber, wood fiber, or other natural fibers), polymer fibers (including polyester, polyethylene, aramid—i.e., aromatic polyamide, and/or polypropylene), protein fibers (e.g., sheep wool), and combinations thereof. Depending on the specific type of material, the fibers 130 may either be hydrophilic (e.g., cellulosic fibers) or hydrophobic (e.g. fiberglass, mineral wool, rock wool, stone wool). The fibers may be present in an amount ranging from about 5 wt. % to about 99 wt. % based on the total dry weight of the body-including all values and sub-ranges there-between.

A face coating may comprise a binder, a pigment, and optionally a dispersant.

Non-limiting examples of a binder include polymers selected from polyvinyl alcohol (PVOH), latex, an acrylic polymer, polymaleic anhydride, or a combination of two or more thereof. Non-limiting examples of a latex binder may include a homopolymer or copolymer formed from the following monomers: vinyl acetate (i.e., polyvinyl acetate), vinyl propinoate, vinyl butyrate, ethylene, vinyl chloride, vinylidene chloride, vinyl fluoride, vinylidene fluoride, ethyl acrylate, methyl acrylate, propyl acrylate, butyl acrylate, ethyl methacrylate, methyl methacrylate, butyl methacrylate, hydroxyethyl methacrylate, hydroxyethyl acrylate, styrene, butadiene, urethane, epoxy, melamine, and an ester. Preferably the binder is selected from the group consisting of aqueous lattices of polyvinyl acetate, polyvinyl acrylic, polyurethane, polyurethane acrylic, polystyrene acrylic, epoxy, polyethylene vinyl chloride, polyvinylidene chloride, and polyvinyl chloride.

The face coating may be a color surface coating. The term “color surface coating” refers to a surface coating comprising a color pigment and the resulting surface coating exhibits a color on the visible color spectrum—i.e., violet, blue, green, yellow, orange, or red. The color surface coating may also have a color of white, black, or grey. The color surface coating may further comprise combinations of two or more colors-such a primary color (i.e., red, yellow, blue) as well as an achromatic color (i.e., white, grey).

A non-limiting example of a color surface coating may be pink and produced from a combination of red and white pigments. Another non-limiting example of a color surface coating may be green and produced from a combination of blue and yellow pigments. Another non-limiting example of a color surface coating may be brown and produced from a combination of red, yellow, and black pigments.

The pigment may be an inorganic pigment. Non-limiting examples of inorganic pigment include particles of carbon black, graphite, graphene, copper oxide, iron oxide, zinc oxide, calcium carbonate, manganese oxide, titanium dioxide and combinations thereof. The inorganic pigments may include individual particles having colors selected from, but not limited to, red, blue, yellow, black, green, brown, violet, white, grey and combinations thereof. The particles that make up the first pigment may have a particle size ranging from about 15 nm to about 1000 μm—including all sizes and sub-ranges there-between.

Ceiling tiles other than the acoustic tiles described above can also be used in embodiments of the invention. For example, tiles made from metal, wood, plastic, composites, or other materials can be used.

Materials

The bracket 400 and clip 500 may be constructed metal, carbon fiber, plastic, wood, or composite materials. In one embodiment, the bracket 400 is made of die cast aluminum.

In summary, the present invention provides installers with the option of moving past squares and rectangles to incorporate more ornamental designs into their ceiling grid designs.

Although illustrated and described above with reference to certain specific embodiments, the present invention is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the invention. It is expressly intended, for example, that all ranges broadly recited in this document include within their scope all narrower ranges which fall within the broader ranges.