Ceiling System

The present application is a continuation of U.S. Nonprovisional patent application Ser. No. 18/433,792, filed Feb. 6, 2024, which in turn is a continuation of U.S. Nonprovisional patent application Ser. No. 18/382,283, filed Oct. 20, 2023, now U.S. Pat. No. 11,933,045, which in turn is a continuation of U.S. Nonprovisional patent application Ser. No. 17/534,051, filed Nov. 23, 2021, now U.S. Pat. No. 11,834,827, which in turn is a continuation of U.S. Nonprovisional patent application Ser. No. 16/566,444, filed Sep. 10, 2019, now U.S. Pat. No. 11,199,004, which in turn is a continuation of U.S. Nonprovisional patent application Ser. No. 15/639,604, filed Jun. 30, 2017, now abandoned, which in turn claims priority to U.S. Provisional Patent Application Ser. No. 62/357,049, filed Jun. 30, 2016, and U.S. Provisional Patent Application Ser. No. 62/517,651, filed Jun. 9, 2017, the entireties of which are hereby incorporated by reference herein as though fully set forth herein.

The instant disclosure relates to a drop ceiling product, a system for dynamic acoustic drop ceiling product, along with the methods for installing the drop ceiling product. In particular, the instant disclosure relates to a dynamic acoustic drop ceiling systems that include multiple differently shaped product, components or slats, configured to be quickly and easily installed into a backer panel to create a tile. The tile is then inserted or installed onto drop ceiling hangers or a t-grid to provide an aesthetically pleasing image, such as an undulating image, along with a reduction in unwanted noise and/or room acoustics.

The instant disclosure further relates to an apparatus that is configured using recycled polyester felt or PET Felt, and in an embodiment, provides for numerous differently shaped components that when installed in a repeating pattern, as detailed below, create an undulating effect or image. Each drop ceiling product is configured from a piece of PET Felt and contains one or more installation slots, that allow for the drop ceiling product to be installed first into a backer panel and then into the drop ceiling hanger without any extra tools, clips or additional hardware.

In general terms, drop ceilings are suspended below the actual ceiling to restrict the view of the ceiling and create a more appealing view from the floor. Suspended drop ceilings are usually hung at a distance below the structural members to hide mechanical and electrical equipment, along with electrical conduit, HVAC ducts, water pipes, sewage lines, lighting fixtures, and similar structures. In order to construct a suspended drop ceiling, a metal grid is suspended from the actual drop ceiling, usually by wires, and acoustical or similar tiles, are inserted and supported by the grid.

In order to minimize excessive and/or unwanted sound generated because of the exposed ceiling, one solution is to hang product from the ceiling at certain intervals to allow for the exposed ceiling to be viewed, but to reduce the acoustic profile. As an example of a structure intended to reduce unwanted noise is the Supported Architectural Structure disclosed and claimed in U.S. Pat. No. 8,782,987, to Kabatsi et al., which discloses a plurality of primary supports configured to couple with one or more architectural structures, and a plurality of flexible fins is incorporated into the structure using primary supports, secondary supports and attachment points.

Another example of a drop ceiling structure is U.S. patent application Ser. No. 10/774,233, to Stackenwalt et al., which discloses a decorative structure, which may be curved, suspended within a space and which includes a panel fastened to a support structure by a clip, a portion of which extends along a face of the panel.

These examples utilize additional supports, attachment hardware and clips to assist in suspending the flexible fins or decorative panels to the drop ceiling or to drop ceiling structure. In doing so, each of these examples necessitate tools to assemble the structure and to suspend the structure to the drop ceiling or drop ceiling support structure.

As such there is a need for a dynamic acoustic drop ceiling system that includes multiple shaped ceiling product that can be quickly and easily installed onto existing construction drop ceiling hangers or similar support structures without the need for tools, separate attachment devices, clips or the like. There is also a need for a dynamic acoustic drop ceiling system that is an aesthetically pleasing image, such as an undulating image, along with the function of reducing unwanted noise.

The foregoing is intended only to illustrate the present technical field and background art and should not be taken as a limitation or disavowal of claim scope.

The present disclosure is an improved acoustic drop ceiling product, and an improved dynamic acoustic drop ceiling system, along with improved methods for installing the drop ceiling product and creating the dynamic acoustic drop ceiling system. The improvement comprises drop ceiling components that are configured with installation slots to be quickly and easily installed into backer panels to create different tiles. These tiles are then installed into or on drop ceiling hangers or drop ceiling structures, to provide an aesthetically pleasing image, such as an undulating image, along with functioning to reduce unwanted noise or room acoustics. Additionally, the drop ceiling components can be installed directly into the drop ceiling hangers without the backer panels to hold the components in place.

The present disclosure comprises a drop ceiling product that is manufactured from a recyclable and/or recycled material, such as recycled polyester felt or PET Felt, and in an embodiment, provides that each drop ceiling product is configured from a piece of the PET Felt for strength. In this embodiment, the drop ceiling product is generally a rectangular shape with a straight edge top and straight edge sides. Each drop ceiling product comprises an installation slot and the bottom edge of each drop ceiling product is usually different from the others depending on the design. In general, the drop ceiling product repeats at some point in the design. By repeating the shape, less ceiling product designs are needed for particular designs, as detailed below. This drop ceiling product configuration (with the installation slots) allows for the drop ceiling product to be installed into a backer panel and then into the drop ceiling hanger or t-grid without the need for tools, clips or any additional attachment devices. The configuration of the backer panel, once installed, may block the view of the drop ceiling hanger or t-grid from the floor below the ceiling, thereby increasing the aesthetically pleasing image of the drop ceiling system.

The present disclosure further relates to an improved dynamic acoustic drop ceiling system comprising a number of differently shaped drop ceiling product that can be installed into a drop ceiling structure such that the system, as a whole, provides an aesthetically pleasing image, such as an undulating image, based on the placement of the differently shaped drop ceiling product. As a non-limiting example, sixteen drop ceiling product designs can make up a single tile (either with the backer panel or without) that can be replicated at different locations in a room ceiling. By strategically placing the tiles (each made up of sixteen drop ceiling product) in multiple different locations, the ceiling design can be modified. Further, depending on the drop ceiling product for a particular tile, there may only be eight designs necessary, as reversing the ceiling product may provide the desired effect, to create an undulating image.

The present disclosure also relates to an improved method of installing the drop ceiling product and/or backer panel loaded with the drop ceiling product. This method allows for the creation of a dynamic acoustic drop ceiling system, in which the acoustic drop ceiling product are installed into the drop ceiling structure by placing the installation slots of each drop ceiling product into the backer panel and then onto the existing drop ceiling hanger, without the need for additional tools, clips or additional attachment devices, to provide an aesthetically pleasing image, and to function to reduce unwanted noise or room acoustics.

It is thus an objective of the present disclosure to provide an improved acoustic drop ceiling product, comprising installation slots, which allow for the drop ceiling product to be installed into a backer panel and then into an existing drop ceiling hanger without the need for tools, clips or additional attachment devices.

It is yet another object of the present disclosure to provide an improved dynamic acoustic drop ceiling system in which the improved drop ceiling product are installed in a manner and pattern that creates an aesthetically pleasing image and functions to reduce unwanted noise or room acoustics.

It is yet another objective of the present disclosure to provide an improved method for installing the improved drop ceiling product and thereby creating the dynamic acoustic drop ceiling system with an aesthetically pleasing image and which functions to reduce unwanted noise or room acoustics.

In a further aspect, the invention can be a ceiling system comprising: a backer panel comprising: a top surface; a bottom surface opposite the top surface; and a plurality of openings extending from the top surface to the bottom surface; a plurality of ceiling components, each of the plurality of ceiling components comprising: a main body; and a pair of tabs protruding upward from the main body and configured to engage first and second ceiling hangers of a ceiling hanger system; and the plurality of ceiling components assembled to the backer panel to form a ceiling tile in which: (1) the main bodies of the plurality of ceiling components are below the backer panel; and (2) the pairs of tabs of the plurality of ceiling components pass through the plurality of openings and protrude from the top surface of the backer panel to allow mounting of the ceiling tile to the ceiling hanger system via the pairs of tabs engaging the first and second ceiling hangers.

In an even further aspect, the invention can be a ceiling system comprising: a ceiling hanger system comprising a plurality of ceiling hangers arranged in a rectilinear grid defining a plurality of grid openings; a plurality of ceiling tiles, each of the plurality of ceiling tiles comprising: a backer panel formed of an acoustic absorbing material and comprising a top surface, a bottom surface opposite the top surface, and a plurality of openings extending from the top surface to the bottom surface; a plurality of ceiling components formed of an acoustic absorbing material and assembled to backer panel, each of the plurality of ceiling components comprising a main body below the bottom surface of the backer panel and at least one tab extending upward from the main body that passes through one of the plurality of openings of the backer panel and protrudes from the top surface of the backer panel; and the plurality of ceiling tiles mounted to the ceiling hanger system via the tabs of the plurality of ceiling tiles engaging the plurality of ceiling hangers.

In another aspect, the invention can be a ceiling system comprising: a backer panel formed of a felt material and comprising: a top surface; a bottom surface opposite the top surface; and a plurality of openings extending from the top surface to the bottom surface; and a plurality of linear ceiling components formed of a felt material, the plurality of linear ceiling components mounted to the backer panel adjacent the bottom surface of the backer panel in a parallel arrangement to form a ceiling tile, each of the plurality of ceiling components comprising a plurality of tabs that extend through the openings of the backer panel and protrude from top surface of the backer panel, each of the tabs comprising an outwardly-facing recess that is configured to receive and engage an edge of a ceiling hanger of a ceiling hanger system to mount the ceiling tile to the ceiling hanger system.

In another aspect, the invention can be a ceiling system comprising: a plurality of ceiling tiles comprising: a felt backer panel comprising: a top surface; a bottom surface opposite the top surface; and a plurality of felt ceiling components mounted to the backer panel so that the plurality of felt ceiling components extend substantially parallel to one another along a bottom surface of the felt backer panel; and a ceiling hanger system comprising a plurality of ceiling hangers arranged in a rectilinear grid defining a plurality of grid openings; the plurality of ceiling tiles mounted to the ceiling hanger system so that each of the plurality of ceiling tiles encloses one of the plurality of grid openings.

In a further aspect, the invention can be a ceiling system comprising: a ceiling hanger system comprising a plurality of ceiling hangers arranged in a grid defining a plurality of grid openings, each of the ceiling hangers being an inverted T-beam having horizontal flange portions; a plurality of ceiling tiles comprising: a first spacer bar; a second spacer bar; a plurality of felt slats coupled to the first and second spacer bars, the felts slats being parallel to one another and orthogonal to each of the first and second spacer bars, the first and second spacer bars being spaced from one another, each of the plurality of felt slats extending from a first end to a second end and comprising: a first recess at least partially defined by a first floor below the first recess and a first roof above the first recess; and a second recess at least partially defined by a second floor below the second recess and a second roof above the second recess; and each of the ceiling tiles mounted to the ceiling hanger system so that: (1) the horizontal flange portion of a first one of the ceiling hangers extends into the first recesses of the felt slats and engages the first roofs of the first recesses; and (2) the horizontal flange portion of a second one of the ceiling hangers extends into the second recesses of the felt slats and engages the second roofs of the second recesses.

In another aspect, the invention can be a ceiling system comprising: a plurality of ceiling tiles, each of the plurality of ceiling tiles comprising: at least one member; a plurality of felt slats coupled to the at least one member so as to be maintained parallel to one another, each of the felt slats comprising: a main body; a first tab comprising a first base portion extending upward from a top side of the main body and a first arm portion extending from the first base portion in a first direction toward a first end of the main body to form a first open recess, the first open recess having a first floor formed by a first portion of the top side of the main body and a first roof formed by an undersurface of the first arm portion; a second tab comprising a second base portion extending upward from a top side of the main body and a second arm portion extending from the second base portion in a second direction opposite the first direction toward a second end of the main body to form a second open recess, the second open recess having a second floor formed by a second portion of the top side of the main body and a second roof formed by an undersurface of the second arm portion; each of the first and second recesses configured to receive a flange portion of opposing ceiling hangers of a ceiling hanger system to mount the ceiling tile to the ceiling hanger system.

In a further aspect, the invention can be a ceiling system comprising: a ceiling hanger system comprising a plurality of ceiling hangers arranged in a grid defining a plurality of grid openings, each of the ceiling hangers comprising flange portions; a plurality of ceiling tiles comprising: a first spacer bar; a second spacer bar; and a plurality of felt slats coupled to the first and second spacer bars that are spaced from one another, each of the plurality of felt slats comprising: a first recess at least partially defined by a first floor below the first recess and a first roof above the first recess; and a second recess at least partially defined by a second floor below the second recess and a second roof above the second recess; and each of the ceiling tiles mounted to the ceiling hanger system so that the flange portions of opposing ones of the ceiling hangers respectively extend into the first and second recesses of the felt slats and respectively engage the first and second roofs of the first and second recesses.

Additional objectives and advantages of the present disclosure will become apparent to one having ordinary skill in the art after reading the specification in light of the drawing figures, however, the spirit and scope of the present invention should not be limited to the description of the embodiments contained herein.

As stated herein, the objective of the present disclosure is to provide an improved acoustic drop ceiling product, and an improved dynamic acoustic drop ceiling system, along with improved methods for installing the drop ceiling product on or into a drop ceiling hanger system or t-grid to create the dynamic acoustic drop ceiling system.

Referring to the drawings, wherein like reference numerals refer to the same or similar features in the various views,show different views of the improved drop ceiling product, tile sections (or tiles)and system, which in the preferred embodiment shown inis a single piece of polyester felt or PET Felt. Each tile sectionreplaces aboutinches byinches of ceiling space, and each drop ceiling productis about 1 foot, 11 ⅞ inches long, with varying heights throughout the length to provide the undulating image.

The drop ceiling productextends from a first endto a second endand generally has two straight sidesand a straight top side. The bottom side, which is seen from the floor when the drop ceiling productor tile sectionis installed in the ceiling, is either straight or has a curve. When multiple different shaped drop ceiling productsare installed in a backer panel (or installed directly onto the ceiling hangers) to create a tile section, an undulating image is formed when viewed from the floor.

The drop ceiling productis made from 9 mm thick PET Felt and comprises one or more installation slots (i.e., tabs), usually two, on the drop ceiling productfor installation purposes. Each installation slot/tabhas a tapered edgeand a recesssuch that when the drop ceiling productis pushed up into the backer panel, the tapered edgewill deform and/or move around the backer panel(or the t-grid) and then return to the original shape locked into the backer panel. The slots/tabsprotrude from the top sideof a main bodyof the drop ceiling product. The slots/tabsinclude a base portionextending upward from the top sideof the main bodyand an arm portionextending from the base portion. The recesshas a floorformed by a portion of the top sideof the main bodyand a roofformed by an undersurface of the arm portion.

shows a perspective and side view (A-A) of a standard drop ceiling hanger system. The standard drop ceiling hangeris normally configured and sized to hold an acoustic tile (not shown), approximately 2 feet by 2 feet, although different size tiles are available, by laying the tile onto the edges of the hangerin a cantilever arrangement. In doing so, the installed tile blocks the view of the actual ceiling, and in some cases, sprinkler systems and vents (not shown) have to be extended to be accessible to the area below the tile.

shows a perspective views of four tilesA, B, C and D being installed into a prior art standard drop ceiling hanger systemcomprising drop ceiling hangers. Each drop ceiling productis combined with other drop ceiling productof the same or different shape to generate a tile sectionand then a drop ceiling system(). The drop ceiling productcan be installed individually onto the t-grid, or installed onto a backer panelfor easier installation onto the drop ceiling hanger system.

shows the ceiling systempartially assembled after installation of tile sectionsA, B, C and D. Each of the tiles, A through D, are made up ofseparate acoustic drop ceiling products, as an example. Thedrop ceiling productsmay each be a different size and shape, or some or all of the productsmay be the same size and shape, thereby creating different designs. For example, tile Amay comprisedrop ceiling productsof which there are eight sets of two similar size products arranged from maximum depth to minimum depth and back again.

Tile C, on the other hand may haveidentical drop ceiling products, and by combining the different tiles, which are made up of the different drop ceiling products, an undulating design can be created, and based on the spacing between each drop ceiling product, sprinkler systems and vents may not have to be extended.

shows the drop ceiling systemmade up of multiple tile sections, which are made up of multiple drop ceiling products. Each of the drop ceiling producthas been installed (directly or with a backer panel) onto the drop ceiling hanger systemby using the drop ceiling hangers.

show exemplary tilesA, B, C and D. These tilesare merely examples of the different drop ceiling productsthat can be used to create the individual tiles. For example,include a perspective view (), plan view (), side elevation view (), and front elevation view (), of the dynamic acoustic drop ceiling tile section A, as previously shown in. Tile Ais installed in a prior art standard drop ceiling hanger, in accordance with the present disclosure. As exemplified, the drop ceiling productsare in the form of slats. The drop ceiling productsare coupled to first and second spacer bars,. The main bodyof the drop ceiling productscomprises opposite major surfaces..

Installed next to tile Ais tile B, also shown in, which include a perspective view (), plan view (), side elevation view (), and front elevation view (). The dynamic acoustic drop ceiling tile section B, as previously shown in, is assembled and located next to tile Ain the prior art standard drop ceiling hanger, in accordance with the present disclosure.

Likewise, next to tile Bis tile C, as shown in, and which include a perspective view (), plan view (), side elevation view (), and front elevation view (). The dynamic acoustic drop ceiling tile C, as previously shown in, is assembled and located next to tile Bin the prior art standard drop ceiling hangerin accordance with the present disclosure.

Finally, next to tile Cis tile D, as shown in, and which include a perspective view (), plan view (), side elevation view (), and front elevation view (). The dynamic acoustic drop ceiling tile D, as previously shown in, is assembled and located next to tile Cin the prior art standard drop ceiling hangerin accordance with the present disclosure. Together, these four tile sectionscreate an undulating design as seen from the floor of the room.

As also shown in, the tile sectionsA, B, C and D can be repeated continuously throughout the room to continue the undulating design effect and to create the drop ceiling system.

show top and bottom perspective views, respectively, of an embodiment to the present disclosure that includes a backer panel or tile cap. The backer panelcan also be made of felt, similar to the drop ceiling productdisclosed herein. Each of the drop ceiling productcan be installed into the backer panel, as described herein, thereby intersecting with the drop ceiling productof the tile sectionsto provide additional acoustic dampening and further blocking the view of the ceiling. Of course, the backer panelmay be made of other materials.

In an alternative embodiment, there can be four types of tile sectionA, B, C and X to make up a drop ceiling system.shows these four tile sectiontypes, with type Ausing various drop ceiling productto have a tile section that shows undulating on one side, to undulating on the other side. Tile section Buses various drop ceiling productto create a tile sectionthat undulates on one sideand is flat or straight on the other side. Tile section Cuses the straight drop ceiling productto create a tile sectionthat is straight or flat on both sides. Tile section Xdoes not use any drop ceiling product. These last tile sectionsare used on boundary conditions and have no pattern. Using these tile sectionsA, B, C and X, a drop ceiling systemcan be generated by placing similar sides together.

shows the assembly of a tile sectionusing a backer paneland various drop ceiling product. The example shown here is similar to tile section Ain which the drop ceiling productgoes from undulating on one sideto undulating on the other side. The two installation slotsof each of thedrop ceiling productare pushed through the indentsof the backer paneluntil the drop ceiling productis locked into place and rests on the backer panel, as shown enlarged in.

Each drop ceiling productcan have a component tag, which details which tile sectionthe productis to be installed and where on that tile section. For example, the third drop ceiling product on the tile section A1 may have a component tagthat reads A1-3.

Once all of the drop ceiling producthave been inserted into the backer panel, such that the installation slotshave pushed through the backer panel indents, the tile sectionwill look likefrom above. The tile sectionis now ready to be installed onto the t-grid or drop ceiling hanger system.

show the tile sectioninstallation onto the drop ceiling hangers(which are exemplified in the form of inverted T-beams having horizontal flange portions).shows the tile sectionplaced at an angle so that one edgeof the productcan slide onto the hangerso that the installation slotwill travel over the edgeof the hanger(see). Next the tile sectionis rotated and popped into place with the installation slotat the opposite edgeflexing then snapping back to form over the opposite edgeof opposite hanger. Once completed, each side and each drop ceiling productwill look similar to, which is an enlargement of. By installing the tile sectionin this manner, the outside section of the backer panelcan partially or totally obscure from view the bottom side of the hanger, for anyone standing on the floor looking up at the ceiling.

show sample groupings for a drop ceiling systemusing four tile sections, with tiles A1and A2, each used twice (), and tiles B1, B2, B3and B4, each used once (). Clearly, numerous tile sectionscan be generated and therefore numerous designs can be created using a small number of differently shaped products.

As described herein, the material used in the preferred embodiment is polyester felt and is 99% recycled. The ceiling bafflesin the preferred embodiment are 9 mm thick, with a standard size of 24 inches by 24 inches, and a maximum size of 24 inches by 48 inches, for 2′ by 2′ and 2′ by 4′ drop ceilings, respectively. The edge options are exposed felt, and maintenance includes occasional vacuuming to remove particulate matter and air-borne debris or dust. Compressed air can be used to dust off the material in difficult to reach areas and for large assemblies.

The felt comes in numerous colors, including white, cream, light grey, light brown, brown, matte grey, charcoal, black, yellow, mango, orange, red, lavender, lime, green, light blue and dark blue. Of course, the ceiling bafflescan be manufactured in many other colors and the present disclosure is not limited to these specifications and colors, as these are merely the specifications and colors for the preferred embodiments and alternative embodiments.

shows a chart for the acoustic testing standard ASTM C423 for the drop ceiling productin the preferred embodiment. The chart indicates testing on the preferred embodiment and provides the results of the sound absorption coefficient for the drop ceiling productat various frequencies. The test arrangement used a +100 mm air layer filled with 50 mm rock wool board. As described herein, the noise reduction coefficient at 500 Hz 70 is 0.76 66, and at 1000 Hz 74 is 1.00 68. Further, the drop ceiling productis fire rated as UL tested ASTM E-84: Class A.

shows the graphof the sound absorption coefficient against frequency for the same test, with the sound absorption average (SAA)of 0.76, and the noise reduction coefficient (NRC)of 0.75.

Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment”, or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment”, or the like, in places throughout the specification are not necessarily all referring to the same embodiment.