A Ceiling Apparatus and Method Thereof

The invention relates to a ceiling apparatus of geometrical shaped closed linear elements in customized shapes. More particularly, the invention relates to a suspended ceiling system comprising of linear elements which offers better aesthetics and hosts services such as acoustics, HVAC, Electrical, Fire Systems, light fixtures, CCTV, PA systems, decorative features and other services which are deemed necessary to be suspended or fixed from True Ceiling providing an aesthetic value to the indoor space with acoustic and light diffusing properties.

Linear elements are hanging ceilings that create an ideal atmosphere inside a closed space. They provide a view to any plenum area and concrete ceiling above. They are also used as a remedial installation to control unwanted acoustic issues such as noise and echo effectively, where a distinctive design or improvement is required. They also act as an acoustic element even while partially hiding from the ceiling. However, builders often face challenges while fixing the ceiling linear elements along with HVAC, Electrical, Fire Systems, light fixtures, CCTV, PA systems, decorative features.

Conventional methods of false ceiling include using one or more materials such as gypsum boards, mineral fibre boards, metal-based profiles, PVC, wood, calcium silicate, high pressure laminates, which have the disadvantage of being heavy and expensive. Each of the mentioned materials have limitations in terms of complete integration of the services, environmental benefits, usage restrictions, thermal insulation, durability, availability, lead time, case of installation, cost of production, depleting natural resource, flaking, dust, case of repair and service, constant maintenance, painting, formation of cracks, aesthetic appeal.

Some prior arts relate to a ceiling linear element system only for acoustics and decorative purposes, other features are independently mounted and methods thereof, where the linear elements can be installed onto construction ceiling hangers, to provide an aesthetically pleasing image, such as an undulating pattern, with a reduction in unwanted noise or room acoustics.

Other prior arts relate to noise reduction apparatus and method of making and using the same, where the panels have holes to receive the rein for absorbing the sound waves between the panels. The panels are attached to the frame or other connecting structure over a workspace. The light fixture is incorporated to the true ceiling separately with the panel which hangs from the ceiling. The panels are made of glass, wood, or other types of material.

These prior arts discuss about a quick and easy installation onto ceiling hangers without the need for additional tools, noise reduction and with different engineering designs and material of the linear elements. However, none of the prior arts provide a solution to the weight of the linear element's material, an additional space for electrical wiring in its design, utilization of a simple and minimal support structure for the linear element, along with facilitating the acoustics, firefighting systems, and Integration of lighting fixtures within the linear elements.

Thus, in light of the above discussion, it is implied that there is need for a system and method for a linear element ceiling, which is reliable and does not suffer from the problems discussed above.

The principal object of this invention is to provide a simplified structure of a ceiling apparatus comprising a light weight and rigid material for a linear element and offer higher UV resistance.

A further object of the invention is to provide a minimal support structure for suspending the linear element from the true ceiling.

Another object of the invention is to provide a space with one or more chambers for electrical wiring, with less installation process.

Another object of the invention is to provide a ceiling apparatus comprising lengthier linear element made of less heavy material to avoid multiple assembling during installation.

Another object of the invention is to provide a ceiling apparatus comprising acoustic properties by employing perforated and infusing acoustic materials.

Another object of the invention is to provide a ceiling apparatus with multiple chambers to accommodate Various direct and indirect lighting elements within the profile.

Another object of the invention is to provide a ceiling apparatus comprising an infill which acts as both acoustic and light diffusing and reflecting properties, as well as creating a complete look and making it visually appealing.

Another object of the invention is to provide a ceiling apparatus comprising special fixing brackets for sprinklers, alarms in the structure without disturbing its function, the aesthetic look or arrangement of a suspended ceiling.

Another object of the invention is to provide a ceiling apparatus which fixes linear elements to utilize minimal/no mechanical fixtures or fasteners to install into the Carriers.

Another object of the invention is to provide a ceiling apparatus providing provision for HVAC within the suspended ceiling.

Another object of the invention is to provide a ceiling apparatus comprising different geometrical patterns using the linear element.

Another object of the invention is to provide a ceiling apparatus comprising an apparatus of light weight material which has good durability.

Another object of the invention is to provide a ceiling apparatus comprising a linear element which can be used for both interior and exterior applications.

Another object of the invention is to provide a ceiling apparatus to reduce the installation costs, easy to dismantle and reuse the linear element, and provides cost effective recycling, thereby adding further environmental benefits.

A suspended ceiling system is a structure that comprises anchor fasteners, suspension rods, carriers, linear elements, and surface installing appliances.

The anchor fasteners are designed to provide a firm support to at least one surface, and the suspension rods are used to create an adjustable gap between the surface and the carrier.

The linear element, which is connected to the carrier, provides a housing for casing the surface installing appliance, and it can be made of different materials such as UPVC, steel, and wood, depending on the user's requirements.

The carrier comprises a slot and a hole to connect the suspension rod and the linear element by mechanical fixtures, and an infill that provides additional support for mounting the surface installing appliance, creating a complete look, and making it visually appealing.

The system is versatile and can be modified based on user requirements, such as changing the shape and height of the linear element, rearranging the cross web to create more space in the partition, and attaching the linear element to one another for mounting the surface installing appliance.

The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and/or detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this invention will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, arc intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).

As used herein, the term “comprising” means that other steps and other components that do not affect the end result may be utilized. The term “comprising” encompasses the expressions “consisting of,” and “consisting essentially of.” The expression “effective amount,” as used herein denotes an amount of a compound or composition sufficient to significantly induce a positive benefit, preferably an oral health benefit, but low enough to avoid serious side effects, i.e., to provide a reasonable benefit to risk ratio, within the sound judgment of a person having ordinary skill in the art. The use of singular identifiers such as “the,” “a,” or “an” is not intended to be limiting solely to the use of a single component but may include multiple components.

The present invention focusses on utilizing a lightweight material, which is also rigid and acts as a good replacement for the conventional materials used for linear elements.

The linear element can refer to a board or partition used to direct or control the flow of air, water, or heat. For example, a linear element may be installed in an attic to control the flow of air and prevent heat loss.

In an embodiment, the linear element material used is Un-plasticized Polyvinyl Chloride (UPVC), which has great properties comprising strength, durability, enhanced fire properties, erosion and is also recyclable.

In an embodiment, the linear elements made of UPVC, which comprise elongated structures in the shape of square or rectangular closed boxes in multiple widths and heights. These linear elements can be placed in singular size or in a plurality of sizes with standard/custom spacing between the linear elements or custom patterns as per the user's design requirement. The linear elements can be fixed or positioned to predrilled metal carriers or angles in a defined spacing or custom spacing suspended from the true ceiling. These elongated structures are henceforth termed as linear elements and the linear elements are not constricted to any geometrical shapes, and may comprise one or more shapes comprising square, rectangular, triangular, oval, circular, any polygonal shaped, and the like.

In an embodiment, the UPVC material used is obtained by twin-screw extrusion process for good efficiency. The twin-screw extrusion process provides better control of process parameters, remarkable mixing capability, high level of process flexibility, better control of process parameters, higher process productivity, saving power and reducing cost of production, continuous production process unlike batch process in single screw extruder.

The composition of this material comprises PVC of 75% to 80%, as well as at least one of CaCO3, TiO2, impact modifier, processing aid, and CaZn stabilizer. The UPVC linear elements extruded in the twin-screw extrusion method are more suitable for shaping into any shapes such as square or rectangular, which can be of pre-defined standard dimensions or customized as per the requirement of the users.

The linear elements made have a density of 1.5 g/cm, which is light in weight and helps in reducing the overall structural load over the true ceiling. When compared to commonly used metals such as aluminium has a density of 2.7 g/cm, steel has a density of 7.9 g/cm. Hence, advantageously, UPVC linear elements considerably reduce the load on structures. The linear element in UPVC material which is 100% recyclable, the process for producing and recycling consumes less energy compared to recycling other metals, which helps in better energy management and thus environmentally friendly. Further, continuous maintenance is required for metal based linear elements as they are prone to weathering.

In an embodiment, the linear elements are in the form of linear elements made of UPVC, but not limited to UPVC it can be at least one steel, wood or wood-based materials, carbon fiber and any other type of materials.

In an embodiment, the term like ceiling, or ceiling system should be understood to include other surfaces like wall, etc., as this invention is equally applicable to such applications.

In an embodiment, the suspended ceilingcomprising simplified support structures as illustrated in, illustrates an isometric view of at least one linear element fixed on to at least one carrier. The figure depicts at least one anchor fastenerwhich is used for providing firm support with at least one surface, to which at least one suspension rodis mechanically fastened to at least one carrier. In an embodiment, for the sake of convenience, the at least one surfaceis considered as a ceiling.

In an embodiment, the at least one carriercomprises rigid support material which has the provision for fixing at least one linear elementin an array. The suspended ceilingfor any space comprises at least one carrier, suspended from the at least one surfaceby means of the at least one suspension rodfixed to the at least one anchor fastener. The at least one carrierare distanced apart at a predefined distance to accommodate the one or more linear elementssuitable for a required length and design configuration.

In an embodiment, the at least one carriercomprises hard metal plates or rods with multiple drilled slots and holes for affixing heavy things using at least one fixtures and fasteners like washers, stove bolts, lag screws, lag bolts, brackets, washers, and bolts suitably. The length and the number of linear elements used in the at least one surfacedecide the length and breadth of the at least one surface. The at least one carrierare in turn supported to the at least one surfaceby means of respective anchoring for the required particular type of at least one surface.

In an embodiment, the at least one surfacecomprises at least one horizontal surface, at least one vertical surface, at least one parallel surface, at least one perpendicular surface.

illustrates a cross sectional view of at least one linear element fixed on to a predrilled slotted angle, in accordance with an embodiment.

illustrates a cross sectional view of at least one linear element is snap fitted to at least one elongated bracket, in accordance with an embodiment.

illustrates a cross sectional view of at least one linear element connected to at least one carrier by means of washer and bolt, in accordance with an embodiment.

In an embodiment, the at least one carrierwith the at least one linear elementmechanically fastened to the at least one carrier. The at least one carriercomprises a slotted L-angle, which shows the slotsin at least one axis of the at least one carrierthroughout its length, where the at least one suspension rodis fastened to one of the slots in the at least one carrierby means of washer and bolt or at least one mechanical fixtures or fasteners.

The at least one linear elementis connected to the at least one carrierby means of at least one bracket, where the extended part of the at least one linear elementis tightly held in between the at least one bracket, and the at least one carrier. The at least one carrieris designed to bear the load of the said invention.

In an embodiment, the at least one linear elementis connected to the at least one carrierby means of at least one bracket, but not limited to the at least one bracketit can be at least one elongated bracketas shown in, and at least one washer and boltas shown in

The at least one bracketor at least one washer and boltor at least one elongated bracket can be developed for various services and is not limited to sprinkler system, speakers, and light fixtures as specified.

In an embodiment, the mechanical fixtures or fasteners are not limited to the ones shown here, accordingly the way of mechanically fixing or attaching the parts may differ to comply with the requirement.