Priority is claimed as a 371 of international application number PCT/IL2011/000161, filed on Feb. 15, 2011; which claims priority to Israeli Patent application serial number 203994, filed on Feb. 16, 2010 and Israeli Patent application serial number 205989, filed on May 26, 2010.
The present invention relates to the field of ceiling panels. More particularly, the invention relates to an apparatus for securing ceiling panels.
Ceiling panels such as acoustical ceiling panels are generally suspended on support members. This invention deals with the type of ceiling panels that esthetically conceal the support members when viewed from below.
Many ceiling panels that conceal the support members are known from the prior art; however, they are liable to be dislodged from the support members and to cause damage when falling from the ceiling.
U.S. Pat. No. 6,108,994 discloses a ceiling panel having first and second opposing edges having different profiles with upper and lower lips. The first edge has a registration step and an access kerf at a first level below the registration step. The second edge has a registration kerf formed by the upper and lower lips at a second level above the first level. When the panel is assembled into the ceiling, the access kerf permits the registration kerf to engage, and form a hinge with, the support grid. The registration kerf permits the panel to be shifted and rotated to engage the registration step with the grid.
This prior art panel is formed by a complicated and therefore costly method for precisely forming the lips and kerfs of the first and second edges, particularly when the panel is made from difficult to cut mineral fiber. An additional drawback of this panel is that the assembly and removal procedures are time consuming, for example an exploratory upward lift is needed to identify the first edge. Also, the panel is liable to be dislodged from the support grid when a random force is applied thereto. Furthermore, two adjacent panels are assembled with significant play therebetween, to take into account the complicated assembly and removal procedures, and therefore side edges of a plurality of assembled panels invariably will not be coplanar, detracting from the esthetic appearance of the ceiling.
Other prior art concealed ceiling panels with other or similar drawbacks are U.S. Pat. No. 6,260,325 and U.S. Pat. No. 6,389,771.
The Casoline GRID panel disclosed in www.british-gypsum.com is provided with metal support sections attached to the upper planar surface of the panel, for engaging the upper face of the flange of a support member generally referred to as a “main runner”. The portions of the support sections that engage the main runner flange are substantially horizontally disposed. The disposition of the engaging portions, and consequently of the entire panel, is therefore dependent upon the disposition of the main runner. However, the main runner, which is generally made of thin-gauge sheet metal, e.g. of 0.4 mm thickness, and sensitive to applied loads, is supported by one or more hangars vertically extending from an overhead surface. Due to assembly inaccuracies, the hangars may not be positioned completely perpendicularly to the overhead surface and a panel supported by two adjacent main runners may be slightly oblique with respect to a neighboring panel as a result of the variance in perpendicularity of adjacent hangers that support a corresponding main runner from above. Thus the side edges of a plurality of assembled panels invariably will also not be coplanar, and adjacent side edges of laterally adjacent panels will not be mutually parallel, detracting from the esthetic appearance of the ceiling.
It is an object of the present invention to provide means for securing a ceiling panel in such a way that it will not be dislodged from adjacent concealed main runners during normal usage, yet is detachable from the main runners upon demand.
It is an additional object of the present invention to provide means for securing a ceiling panel such that the side edges of a plurality of assembled panels will be coplanar.
It is an additional object of the present invention to provide means for diminishing the influence of the hangar disposition on the disposition of the main runner flange and on the panel secured thereto.
Other objects and advantages of the invention will become apparent as the description proceeds.
The present invention provides a ceiling panel assembly for being secured to, and for concealing, a suspended inverted T-shaped, longitudinally extending main runner having a vertically disposed web, a horizontally disposed flange divided by said web to equal flange portions, and a protuberance at a terminal end of each of said flange portions.
The main runner, which is generally made of thin-gauge sheet metal and sensitive to applied loads, is suspended by one or more hangars vertically extending from an overhead surface. Due to assembly inaccuracies, the hangars may not be positioned completely perpendicularly to the overhead surface. The delicate main runner web tends to change its disposition while seeking the least stressed disposition, generally collinear or parallel with the imperfectly installed hangar. In contrast to prior art ceiling panel assemblies which are secured to the main runner flange and therefore become slightly oblique with respect to the underlying floor surface, and at times with respect to a neighboring panel, as a result of the variance in perpendicularity of adjacent hangers that support a corresponding main runner from above, the panel assembly of the present invention stiffens the main runner flange. A change in disposition of the stiffened main runner flange and of the panel assembly secured thereto is therefore resisted.
The panel assembly of the present invention comprises:
a) a main section with a first and second lateral edge and having one or more visible panel sections; and
b) two support sections laterally extending in opposite directions, which are disposed above said main section,
wherein said two support sections releasably contact two adjacent and laterally spaced main runners, respectively, and one of said sections is adapted to multi-directionally stiffen a corresponding main runner.
Preferably a first support section is a multi-directionally stiffening support section for stiffening, e.g. in four translational and in two rotational directions, and unforcibly contacting the flange of a first main runner overlying the main section of a first panel assembly and a second support section is a stabilizing support section for unforcibly contacting the flange of a second main runner multi-directionally stiffened by a second panel assembly laterally adjacent to said first panel assembly.
In one aspect, the multi-directionally stiffening support section comprises a flange abuttable element for engaging a flange portion of the first main runner when the stabilizing support section is raised, to prevent the panel assembly from falling through a ceiling opening.
In one aspect, the multi-directionally stiffening support section is connected to, or integral with, a planar flange-underlying element in unforcible contact with the first main runner flange.
In one aspect, one end of the flange-underlying element laterally extends from the first lateral edge of the main section.
In one aspect, the multi-directionally stiffening section comprises a protuberance-fastening element for unforcibly contacting substantially the entire outer surface of a flange portion protuberance. The protuberance-fastening element has substantially the same curvature as the protuberance. A spacer may be interposed between the protuberance-fastening element and the flange abuttable element.
In one aspect, the multi-directionally stiffening section comprises two elements vertically extending from the flange-underlying element, for unforcibly contacting a corresponding flange portion protuberance.
The flange abuttable element extends from, and is substantially perpendicular to, one of the vertically extending elements, and may extend between the two vertically extending elements.
In one aspect, the two support sections are connected to, or integral with, the one or more panel sections and the flange-underlying element is in abutting relation with a planar upper surface of the one or more panel sections.
In one aspect, the length of the main runner flange is substantially equal to that of the flange-underlying element.
In one aspect, the multi-directionally stiffening support section is dimensioned such that one flange portion of the first main runner overlies the first lateral edge of the main section of the first panel assembly and extends to the second lateral edge of a third panel assembly which is laterally adjacent to the first panel assembly to define a gap between the first lateral edge of the first panel assembly and the second lateral edge of the third panel assembly.
In one aspect, the first lateral edge of the first panel assembly and the second lateral edge of the third panel assembly are straight edges and the gap has a predetermined and uniform width, e.g. of less than 5 mm and preferably less than 2 mm, and all first lateral edges of each of a row of first panel assemblies are essentially coplanar and all second lateral edges of each of a row of third panel assemblies are essentially coplanar.
In one aspect, each of the one or more visible panel sections has a straight bottom edge and all bottom edges of each of a plurality of panel assemblies are essentially coplanar.
In one aspect, the flange abuttable element is spaced from the web of the first main runner by a distance of less than 5 mm, and preferably by a distance of approximately 2 mm, when the stabilizing support section unforcibly contacts the flange of the second main runner.
In one aspect, the stabilizing support section comprises a force appliable element extending from the second lateral edge of the first panel assembly and connected to, or integral with, the main section of the first panel assembly, for unforcibly contacting the protuberance of a flange portion of the second main runner. The force appliable element may be substantially perpendicular to the web of the second main runner.
In one aspect, the main section further comprises a frame member to which the one or more visible panel sections are attachable.
In one aspect, a portion of two adjacent panel sections attached to the frame member are separated by an opening constituting an air chamber through which sounds generated in a room are transmittable so as not to be reflected back into said room.
In one aspect, an ornamental element is attached or applied to one or more of the panel sections, such as attached to two adjacent panel sections.
The present invention is also directed to a frame member for ceiling panels comprising one or more connecting members for interfacing between two separate support sections which are contactable with two suspended members, respectively, and between one or more visible panel sections.
In one aspect, the one or more visible panel sections are attached to the one or more connecting members and are spaced from each other so as to define corresponding openings each of which constituting an air chamber through which sounds generated in a room are transmittable so as not to be reflected back into said room.
In one aspect, the frame member is rectangular and comprises four integrally formed connecting members.
In one aspect, the one or more connecting members support ceiling related apparatus.
In the drawings:
The present invention is a novel ceiling panel that is secured to, while stiffening, an adjacent concealed main runner, so that the side edges of a plurality of assembled panels will be coplanar. Thus an architectural effect can be achieved, which could not have been realized heretofore, whereby a gap of a predetermined and uniform width can be produced between adjacent rows of ceiling panels having coplanar side edges.
The utility of the present invention will be appreciated by referring first to
A metal, inverted T-shaped main runner 10 has a generally vertically disposed web 5 terminating at its uppermost end with a hollow bulb 7 which is suspended from a plurality of hangars 3 attached to an overlying horizontal support surface 37 (
The dimensions of main runner 10 are standardized, e.g. the flange has a lateral dimension of 24 mm and the web has a vertical dimension of 45 mm. The web and flange are generally made of thin, two layered sheet metal. Each layer has a standard thickness of e.g. 0.4 mm, and main runner 10 is therefore easily deformed. The hangars 3 from which each main runner 10 is suspended may be separated by an equal distance of approximately 1.20 m. The lateral dimension between the webs of two suspended main runners is e.g. 61 cm and between two adjacent flanges is e.g. 58.5 cm.
To the planar and substantially horizontal upper surface 2 of prior art panel 15, generally made of a mineral fiber substrate, are adhesively attached metal support sections 16 and 24.
J-shaped support section 16, which is secured to flange portion 9 of main runner 10, has an inwardly extending planar element 18 that is adhesively attached to upper surface 12 of panel 15, adjacent to, and slightly separated from, lateral edge 14 of the panel. The length of element 18 is substantially equal to the length of the flange of main runner 10. A short, substantially vertical element 19 extends from the inward edge of element 18. Retaining element 20 substantially parallel to element 18 outwardly extends from vertical element 19 for a fraction of the length of element 18, which is sufficient to retain flange portion 9 of main runner 10 within the interior of support section 16 after support section 16 has been secured to flange portion 9 and protuberance 12 of flange portion 9 contacts vertical element 19.
Support section 24 has a planar element 28 inwardly extending from lateral edge 17 of panel 15 that is adhesively attached to upper surface 2 of panel 15, and an abutting element 29 vertically spaced from, and substantially parallel to, element 28. Abutting element 29 is positioned outwardly from lateral edge 17 of panel 15, and an oblique element 23 extends from planar element 28 to abutting element 29. Abutting element 29 is adapted to contact main runner 11, i.e. protuberance 12 of its flange portion 8 from above.
The plurality of hangers 3 are generally manually installed to the overlying horizontal support surface, and downwardly extend therefrom for a distance ranging from approximately 0.3-2 m. As the manual installation technique is subject to human error, many of the hangars are invariably not perfectly perpendicular to the overlying horizontal support surface and to the underlying horizontal floor surface, e.g. by a deviation of a few millimeters. Although bulb 7 is suspended from an imperfectly installed hangar 3 such that web 5 is at first essentially perfectly perpendicular to the overlying horizontal support surface, the web seeks the least stressed disposition, which may be collinear or parallel with the imperfectly installed hangar. Thus over the course of time, the bulb becomes repositioned due to the gravitational force, causing the flange of main runner to be slightly oblique with respect to the underlying floor surface. Alternatively or in addition, the main runner becomes deformed over the course of time.
An imperfectly installed hangar 3′ is shown relative to an ideally mounted hangar 3, which is attempted to be mounted perpendicularly to the overlying horizontal support surface and indicated by phantom lines. The flange of main runner 11, which is shown to have changed disposition due to the imperfectly installed hangar 3′, is secured to support section 16 of panel 25. The lateral spacing between the web of main runners 10 and 11 remains substantially equal due to the presence of the cross runners; however the disposition of at least a portion of web 5 of main runner 11 is forced to change in response to the lack of perpendicularity of hangar 3′. Although flange portion 9 of main runner 11 is secured to support section 16 of panel 25, protuberance 12 of flange portion 8 is unrestrained and therefore flange portion 8 of main runner 11 is free to move. As a result of an angular change in disposition of web 5 of main runner 11, flange portion 8 of main runner 11 also angularly changes its disposition by a significant angular change of greater than 1 mm, and sometimes of up to 5 mm, applying a force onto element 18 attached to panel 25 which causes the bottom surface 19′ of panel 25 to be oblique with respect to the underlying floor surface. Since each hanger may be positioned at a different degree of perpendicularity, the bottom surface of each corresponding panel may assume a different orientation, resulting in an esthetically unpleasant and non-uniform appearance.
In contrast, a panel assembly of the present invention comprises two laterally spaced support sections, a first support section for multi-directionally stiffening the main runner flange made of thin-gauge sheet metal to prevent a change in disposition of the main runner, and a second support section for stabilizing the given panel assembly by applying a force onto the main runner flange of an adjacent panel assembly.
Multi-directionally stiffening support section 36, which is shown in
As the main runner flange is unforcibly in contact with the two opposed vertical elements 39 and 49, and elements 39 and 49 have a considerably greater thickness than that of the main runner, e.g. of 1-mm thickness, support section 36 stiffens and strengthens the main runner flange. The strengthened main runner flange, or a main runner web portion, will not deform even though it is loaded by the weight of panel 45 and each flange portion will therefore remain in unforcible contact with the corresponding vertical element. Since each main runner flange unforcibly contacts a corresponding vertical element, substantial angular displacement of the main runner flange is prevented. The main runner flange is therefore considered to be “multi-directionally stiffened”, meaning that substantial displacement thereof in different directions of greater than 1 mm is prevented as a result of the stiffening action provided by the support section. Support section 36 stiffens the main runner flange in the following directions, with respect to the illustrated orientation: (1) towards the right by means of first vertical element 39, (2) towards the left by means of second vertical element 49, (3) downwards by means of flange-underlying element 38, (4) upwards by means of flange-abuttable element 40, (5) clockwise by means of the combination of elements 38-40, and (6) counterclockwise by means of the combination of elements 38-40. Thus multi-directionally stiffening support section 36 prevents the main runner from changing its disposition in four translational and two rotational directions, even if hangar 3 lacks perpendicularity with respect to overlying horizontal support surface 37 with which it is connected and the web 5 seeks the least stressed disposition.
Since the main runners 10 and 11 are multi-directionally stiffened by the corresponding support section 36 and the multi-directionally stiffening support section is anchored within the corresponding panel, all panels are therefore also multi-directionally stiffened. By virtue of being multi-directionally stiffened, the adjacent lateral edges 48 and 44 of contiguous panels 45 and 55, respectively, are assured of remaining in an esthetically pleasing, mutually parallel configuration. In contrast, the adjacent, angularly displaceable lateral edges 17 and 14 of contiguous prior art panels 15 and 25 (
Stabilizing support section 54 is adapted to stabilize panel 45 by being positioned above, and unforcibly contacting, the flange portion associated with adjacent panel 55, and comprises a force appliable element 59 substantially parallel to the upper surface 42 of panel 45. Force appliable element 59 is attached to an L-shaped, or any other shaped, element 53, which is embedded within panel 45. Force appliable element 59 outwardly extends from lateral edge 48 of panel 45, overlying adjacent panel 55 contiguous with panel 45, and is adapted to unforcibly contact main runner 11, i.e. the protuberance 12 of its flange portion 8 from above. Due to the rectilinear configuration of support section 54, force appliable element 59 is also able to unforcibly contact vertical element 49 from above.
In the embodiment of
A panel system 72 assembled according to the teachings of the present invention is illustrated in
In the embodiment of
This clip configuration provides spring-like properties to allow flexibility during a ceiling panel securing operation, as will be described hereinafter. Thus protuberance-fastening element 79 and translation-limiting element 81 are able to cling to protuberance 12 so as to strengthen and stiffen the flange of main runner 11 while providing a multi-directionally stiffening action in the following directions, with respect to the illustrated orientation: (1) towards the right by means of protuberance-fastening element 79, (2) towards the left by means of discontinuity 87 between protuberance-fastening element 79 and translation-limiting element 81, (3) downwards by means of flange-underlying element 78, (4) upwards by means of protuberance-fastening element 79 and translation-limiting element 81, (5) clockwise by means of protuberance-fastening element 79, and (6) counterclockwise by means of protuberance-fastening element 79. Thus multi-directionally stiffening support section 76 prevents the main runner from changing its disposition in four translation and two rotational directions. The elements of support sections 54 and 76 are nevertheless configured with sufficient clearance with respect to corresponding elements of main runner 11, e.g. 0.2 mm, to enable a longitudinal panel sliding operation, as will be described hereinafter.
In
In
The visible panel section of the present invention may be produced from any desired material or materials, including mineral fiber, fiberglass, wood, metal, plastic, plaster, and any combination thereof. The panel sections and support sections are suitably configured so as to conceal the main runners and cross runners. The panel sections may also be acoustic panels for sound absorption or sound insulation.
It will be appreciated that the support sections of any embodiment described herein may be made of other suitable materials as well, such as metal, wood and plastic materials, whether integral with the panel assembly or attached thereto.
In
A ceiling panel securing operation is illustrated in
In order to remove a single panel, e.g. panel 45, the above steps are reversed. That is, panel 45 is first partially raised by applying a force D at its underside in the vicinity of support section 54, to separate force-appliable element 59 of support section 54 from the protuberance of flange portion 8 of main runner 11. Moment M acting on panel upper surface 42 as a result of applied force D is greater than the counteracting moment applied by protuberance-fastening element 79, which is normally sufficiently high to retain panel 45 in a horizontal disposition. Due to moment M, however, protuberance-fastening element 79 of panel 45 becomes separated from protuberance 12 of flange portion 9 and panel upper surface 42 assumes an oblique disposition. Upon a change in disposition of panel 45 while force D continues to be applied, the flange-abuttable element 83 of panel 45 engages flange portion 9 while the angle between flange-abuttable element 83 and the corresponding flange-underlying element 78 continuously increases.
Although panel 45 is obliquely disposed, it is prevented from falling to the underlying floor surface by virtue of the engagement between flange-abuttable element 83 and flange portion 9. In order to ensure that panel 45 will be prevented from falling through the opening in the ceiling when most of the panel is lifted above the main runner flange, the length of flange-abuttable element 83 extending from spacer 82 (
A longitudinal panel sliding operation is illustrated in
In
In
In
The panel assembly of the present invention employing a multi-directionally stiffening support section and a stabilizing support section advantageously remains secured to the main runners even though it is not positioned in abutting relation with an adjacent panel assembly. Thus a panel system 122 shown in
In the embodiment of
To the frame member one or more visible, user selected panel sections are attachable, to produce a customized panel assembly.
As shown for example in
Opening 165 constitutes an air chamber through which sounds generated in the room can be transmitted above panel assembly 160. Thus panel sections 162 and 164 may be made of inexpensive material that is not sound absorbing such as sheet metal or wood, yet panel assembly 160 is afforded good soundproofing qualities by which sounds will be transmitted through opening 165 and will not be reflected back into the room. In addition to the good soundproofing qualities, a panel system 169 employing the plurality of panel assemblies 160A-F is esthetically pleasing as the openings 165 centrally appear in each panel assembly in orderly fashion while a uniform gap 171 defined by the coplanar lateral edges of the adjacent panel rows is evident.
It will be appreciated that the frame member and the visible panel sections can be configured in any desired fashion insofar as the panel assembly is secured to a main runner flange and retained in a substantially horizontal disposition by its support sections. By use of a frame member that interfaces between a support section and a panel section, acoustical, decorative, and artistic effects may be achieved at a dramatically reduced cost that what could have realized heretofore. The frame member may support other ceiling related apparatus, including illumination elements, vents through which conditioned air can circulate, smoke detectors, and sprinklers. The one or more panel sections may be attached to the frame member by any means well known to those skilled in the art.
In the embodiment of
Alternatively, a laterally extending slit 157 may be formed in the panel section 125 so as to be placed in engagement with e.g. lower fin 147 of connecting member 136, as shown in
A frame member 140D shown in
In
While some embodiments of the invention have been described by way of illustration, it will be apparent that the invention can be carried out with many modifications, variations and adaptations, and with the use of numerous equivalents or alternative solutions that are within the scope of persons skilled in the art, without departing from the spirit of the invention or exceeding the scope of the claims.
Number | Date | Country | Kind |
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203994 | Feb 2010 | IL | national |
205989 | May 2010 | IL | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/IL2011/000161 | 2/15/2011 | WO | 00 | 8/20/2012 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2011/101844 | 8/25/2011 | WO | A |
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Entry |
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IPRP CH II of May 15, 2012—along with the Dec. 12, 2011 amendments that the IPRP is based on—28 pages. |
Number | Date | Country | |
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20120304575 A1 | Dec 2012 | US |