Suspended Ceiling Systems Having a Plurality of L-Shaped Panels

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.

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.

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.

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.

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.

depicts an exemplary embodiment of a ceiling systemaccording to the present disclosure. The ceiling systemdepicted includes at least two main beamsrunning substantially parallel to each other. Cross teesrun between the main beams. The cross teesconnect to other cross teeswith bracketshaving clips. Indeed, each cross teeincludes at least one clipadapted to engage with the same type of clipattached to the bracket. By having cross teesattached to bracketsbetween main beamsan ornamental ceiling design may be created. Such ornamental designs may result in grid adapted to receive laid in panelswith unique shapes. For example, at least two cross teesconnected to at least one bracketmay 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).

As depicted in, the ceiling systemincludes both main beamsand intersecting cross tees. Regardless of type, beamsand teesare formed generally of flat sheet metal folded into an inverted T cross section having a weband, a bulbandat the top of the weband, and a horizontal flangeandextending in both directions from the bottom of the weband. The webandis formed of two adjacent layers typically stitchedtogether 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 beamsand teesare not folded metal but instead are made of extruded material, such as metal (e.g., aluminum) or polymers.

The main beamsare typically suspended from a structural ceiling by wires. The main beams, 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 teesare connected to the main beamsthrough slots in the main beams. Such connections form corners. In such a configuration, the cross teesare typically supported by the main beams. Cross teesare manufactured in a manner like main beamsand cross teesand may be cut into lengths of as short as 4 inches (10.2 cm). In other embodiments, beamsand teesmay be cut into lengths of 2, 3, or 4 feet (61 cm, 91 cm, or 122 cm). Cross teesare also connected to bracketsby clips. When cross teesare connected to main beamsand brackets, a ceiling system with a grid adapted to receive laid-in panels is formed.

At least two cross teesare connected to at least one bracketsto form the unique grid design.depict an exemplary embodiment of the bracketsaccording to the present disclosure. The bracketincludes a first sectioncomprising: a first vertical wallextending upward from the approximate center of bottom flanges. The first sectionis connected to a second sectionat approximately a ninety-degree angle, plus or minus 0.75 degrees.

The second sectioncomprising: a second vertical wallextending upward from the approximate center of the bottom flanges.

The bottom flangescommence at the bottom of the first vertical walland second vertical walland extend substantially perpendicularly out in opposite directions from the first and second vertical wallsand.

In one embodiment, there is a cut outwhere the first vertical wallconnects to the second vertical wall. The cutoutmay take on any shape, such as a circle. In certain embodiments, the cutoutmay be located closer to the top edge of the vertical walls,than the bottom flange.

In certain embodiments, the cross teesare taller than the brackets. In such an embodiment, the top of the bracketmay be just above the bottom of the bulbof the cross tee. 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).

As outlined above, the bottom of the bracketincludes the bottom flangethat extends substantially perpendicularly out in both directions from the first and second vertical wallsand. In one embodiment, the flangemay extend past a terminal endof the first vertical wall. In another embodiment, the flangemay extend past a terminal endof the second vertical wall.

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

The flangemay include a step resulting in a portion of the flangeclosest to the first or second vertical wallandresiding in a first plane and the remaining portion of the flangeresiding 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 flangeand. In such a design, the section of the flangecomprising the step may rest on the top of the beam flangeandwith the unsupported portion of the flangeresiding in substantially the same plane as the beam flangeand.

The first and second vertical wallsandeach include a bracket clipattached to the edge opposite the cutout. Two bracket clips, each identical to the other, are used to form a cross tee-bracket connection as seen in. Each bracket clipis roughly rectangular and is formed, by cutting or stamping, from relatively hard material, such as steel, having spring properties. Punched holesand, are above one another, and are formed in the approximate center of the bracket clipas seen in. A third hole,, forming a triangle with the first two, is formed to the rear of the clip, closer to the vertical wallsand.

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

A tongueextends in a direction towards the front of the bracket clipaway from the bracket. In certain embodiments, the grid webhas an offset section or pan formed in the end of the beamand. This pan, which may be rectangular and of a size that slightly exceeds the rectangular dimension of the channel of the clip. Such an embodiment is adapted to permit the channel of bracket clipto 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. Specifically, when the bracket clipis attached to the webin the depressed pan by fasteners, such as flat head rivets past through the pre-punched holes,, andin the pan, the lateral outward face of the bracket clipwill lie in the vertical plane that extends between the layers in the web, which is the vertical center plane of the web.

The beam webandalso has a corresponding beam clip. The beam clipincludes a terminal edgedefined as leading end of the beam clip. The beam clipis located between the bulband flangeof the beam. The topof the beam clipincludes a triangular portion. The topof the beam clipoptionally includes an outwardly disposed flange. The bottom of the beam clipincludes a stop.

The beam clipinclude a fingernailcloser to the terminal edgethan an aperture. The fingernailprojecting outward from the surface of the beam clipin a direction towards the beam. The apertureis adapted to engage with a fingernailof another beam clip.

The beam webandalso has a cutoutandas seen for instance in. This cutoutandreceives a corresponding terminal edgefrom a clipin the form of a terminal edgeprojecting through the cutout. The clipnests in the slot cutoutof the weband serves to secure the clipto the web. Furthermore, the clipmay be secured to the webwith fastener such as rivets.

In certain embodiments of the bracket clip, forward of the stem, the projection extends in a form of an extended circular portion that creates a capin a modified mushroom shape, with the stemextending horizontally when the clipis in place in the ceiling, while the capof the mushroom shape extends vertically providing a horizontal stop.

In certain embodiments, there may be a cutout at the forward part of cap, and a pressed-out detent projecting from the bracket clipbeyond the laterally outward face of the bracket clipat the front of the capadjacent 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 clipare angled outward from the lateral outward face of the clipto form a rear channel. The flanges extend along the rear channel of the clipon the part that lies abutting the web.

A spring pocketis formed on the bracket clip, 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 pocketis joined to the outward face of the clip at a fold line. The entire pocket is stamped from the flat bracket clip, leaving a cutout portion having a rearward pointing arcuate edge.

A clipis fastened to each end of a beamor each sectionof a bracket. The clipsare engaged by forcing one cliplongitudinally into another′′. In certain embodiments, the tongue of a bracket clipengages the pocketof another bracket clipas seen in. This will bring the lateral outward faces and of the bracket clipstogether. The tongue of each bracket clipwill 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.

Detents on each bracket clipwill initially ride within the depressed of stems, 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 clipswill be forced slightly apart as the detents', permitting each clip face to override any portions of the fasteners connecting the bracket clipto the bracketand beams.

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

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 environmentssharing 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 systemprovide 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 fibersmay 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.