Patent Grant
12152388
The present disclosure relates generally to ceiling panel brackets, for example, suitable for forming a ceiling surface by supporting a plurality of ceiling panels. The present disclosure relates more particularly to a carrier for supporting ceiling panels at an angle.
Panels are convenient and effective for constructing architectural surfaces. The panels may be pre-fabricated and shipped to the construction location, allowing for efficient installation that covers a large surface area. If damaged, the panels can be wholly replaced, rather than requiring a custom repair of the architectural surface. In some cases, the panels can be removed to provide access to the area behind the panels.
Panels that are used to form an architectural surface, such as a ceiling, are often supported by a structural grid that holds the panels in place. This allows flexibility in the design of the panels, because the supporting grid provides the structural integrity needed for the architectural surface, thereby allowing the design of the panels to address aesthetic and acoustic requirements of the ceiling system. The panels are typically held in a row or an array to provide an attractive ceiling surface. Panels are often oriented either parallel to the grid so as to form a planar surface, or perpendicular to the grid, such as ceiling baffles. Other configurations are possible, but these are frequently achieved by either customizing the ceiling grid or by hanging the panels with wire from the grid at different lengths. While such building surface structures may be aesthetically interesting, they require the use of various custom configurations and complex installation, thereby increasing installation complexity and costs.
The present inventors have recognized that a ceiling system that allows for an alternative ceiling aesthetic without adding significant complexity in installation would be attractive to architects and builders.
In one aspect, the present disclosure provides a bracket configured to couple a ceiling panel to a ceiling grid, the bracket comprising:
In another aspect, the disclosure provides a ceiling system comprising:
Additional aspects of the disclosure will be evident from the disclosure herein.
The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure.
As described above, the present inventors have noted that a conventional ceiling system that allows for an alternative ceiling aesthetic without adding significant complexity in installation would be attractive to architects and builders.
Accordingly, one aspect of the disclosure is a bracket configured to couple a ceiling panel to a ceiling grid. The bracket includes a support arm configured to extend over a first flange of a grid beam. An attachment wall extends up from the support arm and is configured to be secured to a web of the grid beam. On the other hand, a leg extends down from the support arm so as to hang below the grid beam. A foot is coupled to the leg and is configured to be attached to the ceiling panel. The foot is disposed at a first angle with respect to the support arm so as to hold the ceiling panel at an angle to the ceiling grid.
Such a bracket is shown in perspective view in
In another aspect, the disclosure provides a ceiling system that includes a ceiling grid with a first grid beam, a first bracket coupled to the first grid beam, and a first ceiling panel attached to the first bracket. The grid beam includes a web and a first flange extending laterally from the web. A first bracket according to the disclosure is coupled to the first grid beam. A first ceiling panel is coupled to the foot of the first bracket. The first ceiling panel has a first face and a second face opposite the first face. Moreover, the first ceiling panel extends along a length from a first end to a second end and extends across a width from a first side to a second side.
A portion of such a ceiling system is shown in
As shown in
In certain embodiments of the ceiling system as otherwise described herein, the first grid beam is a T-beam. For example, as shown in
In certain embodiments of the ceiling system as otherwise described herein, the attachment wall of the first bracket is secured against the web of the first grid beam. For example, as shown in
In certain embodiments of the ceiling system as otherwise described herein, at least a portion of the support arm of the first bracket is supported by the first flange of the first grid beam. For example, as shown in
In certain embodiments of the ceiling system as otherwise described herein, the foot of the first bracket is secured against the first side of the first ceiling panel. For example, as shown in
As shown in
In some embodiments, the angle between the support arm and the foot of the bracket is at least 5 degrees, e.g., at least 10 degrees, e.g., at least 15 degrees. Further, in some embodiments, the angle between the support arm and the foot is no more than 85 degrees, e.g., no more than 80 degrees, e.g., no more than 75 degrees. For example, in some embodiments, the angle between the support arm and the foot is in a range from 15 degrees to 75 degrees, e.g., 20 degrees, 30 degrees, 40 degrees, 45 degrees, 50 degrees, 60 degrees or 70 degrees.
In ceiling system 180, foot 150 is fastened to first ceiling panel 170 using a pair of fasteners, such as screws or bolts. In other embodiments, the foot of the bracket is secured to the first ceiling panel using a single fastener or more than two fasteners. Further, in other embodiments, the foot of the bracket is bonded or adhered to the first ceiling panel. In some embodiments, fasteners that hold the foot to the ceiling panel engage the material forming the outer surface of the ceiling panel. In other embodiments, the fasteners extend through the material that forms the outer surface of the ceiling panel. For example, in some embodiments, the outer surface of the ceiling panel is formed by a shell, and the fasteners pass through the outer shell and are secured on the inside of the shell. For instance, in some embodiments, an internal bracket is disposed inside the outer shell of the ceiling panel. Such an internal bracket may be coupled to the foot of the bracket with the outer shell of the ceiling panel sandwiched between the brackets. Still, in other embodiments, fasteners that hold the ceiling panel to the foot of the bracket may be held in place with washers and nuts positioned inside the outer shell of the ceiling panel.
In certain embodiments of the bracket as otherwise described herein, the foot is formed as a flat plate. For example, as shown in
In certain embodiments of the bracket as otherwise described herein, the support arm is formed as a flat plate. Likewise, in some embodiments, the attachment wall is formed as a flat plate. For example, in bracket 100, support arm 110 is formed as a flat plate and attachment wall 120 is also formed as a flat plate that extends upward from the inner edge 116 of support arm 110 so as to be perpendicular to support arm 110. With both the support arm 110 and attachment wall 120 formed as flat plates, the support arm and attachment wall can engage corresponding flat surfaces of the grid beam, as shown in
In certain embodiments of the bracket as otherwise described herein, the support arm and the foot are angled about a lateral axis that is perpendicular to the attachment wall. For example, the angle of foot 150 in bracket 100, as shown in
In certain embodiments of the bracket as otherwise described herein, the foot is laterally offset from the support arm. For example, as shown in
In certain embodiments of the bracket as otherwise described herein, the support arm, attachment wall, leg, and foot are formed in a single integral piece. For example, in some embodiments, the support arm, attachment wall, leg, and foot are formed from a bent metal sheet. For example, bracket 100, shown in
In certain embodiments of the bracket as otherwise described herein, a width of the support arm is substantially the same as a width of the attachment wall. For example, in bracket 100, support arm 110 and attachment wall 120 are formed from a rectangular portion of material with a single bend along inner edge 116. Accordingly, the widths 114, 124 of support arm 110 and attachment wall 120 are the same. In other embodiments, the widths of the support arm and attachment wall may be different. For example, in some embodiments the width of the support arm may be greater than the width of the attachment wall so that the grid beam can provide greater vertical support to the support arm. In other embodiments, the width of the attachment wall may be greater than the width of the support arm, so that the connection between the attachment wall and the grid member can be enhanced.
In certain embodiments of the bracket as otherwise described herein, a width of the foot is substantially the same as a width of the support arm. For example, in bracket 100, width 154 of foot 150 is substantially equal to width 114 of support arm 110. Having the width of the support arm and the foot be similar may allow for a reduction in the amount of material used to form the bracket, as the blanks for a number of brackets can be cut from a single sheet in a row, thereby minimizing wasted material between the cut blanks. On the other hand, the width of the foot may be different from that of the support arm. For example, in some embodiments, the width of the foot may be selected based on the thickness of a ceiling panel that will be held by the bracket. If such a width does not provide an adequate connection to the grid beam, the widths of the support arm and the attachment wall may be larger than the width of the foot, to provide a larger connection area. Likewise, the connection between the foot and the ceiling panel can be increased by increasing the length of the foot without the need to have the foot extend past the edges of the ceiling panel.
In certain embodiments of the bracket as otherwise described herein, a width of the leg is less than a width of the foot. For example, in bracket 100, the width 134 of leg 130 is smaller than the width 154 of foot 150. This decreased width of leg 130 compared to both foot 150 and the thickness of the attached ceiling panel helps obscure leg 130 from anyone viewing the ceiling system from below.
In certain embodiments of the bracket as otherwise described herein, the foot is coupled to the leg at a selectable angle. For example, in some embodiments, the attachment wall, support arm, and leg are part of a grid attachment structure, and the foot is part of a panel attachment structure that is removably coupled to the grid attachment structure so as to form the selectable angle.
Such an embodiment is shown in
In certain embodiments of the bracket as otherwise described herein, the panel attachment structure includes a post extending up from the foot that is coupled to the leg of the grid attachment structure. For example, panel attachment structure 704 of bracket 700 includes a post 756 attached to foot 750. Post 756 is attached to leg 730 using a pair of fasteners 758 that set the orientation of panel attachment structure 704 and, thus, the angle of foot 750 and ceiling panel 770.
In certain embodiments of the bracket as otherwise described herein, the leg includes a series of apertures for adjusting a position of the post so as to secure the foot at the selectable angle. For example, leg 730 of bracket 700 includes an upper aperture 732 and a series of lower apertures 736. The post 756 is secured to leg 730 with a fastener 758 that extends through upper aperture 732 and one of the lower apertures 736 in the series of lower apertures. By choosing one of the selectable lower apertures 736 the angle of the post 756 and foot 750 can be selected. While leg 730 of bracket 700 includes a single upper aperture 732 and a series of lower apertures 736, in other embodiments, the leg of the bracket includes a single lower aperture and a series of upper apertures. By selecting the upper aperture for attachment with the post, the angle of the foot may be selected in a similar manner as with bracket 700. Further still, in some embodiments, the bracket includes a series of upper apertures and a series of lower apertures.
In certain embodiments of the bracket as otherwise described herein, the series of apertures is arranged in an arc. For example, the series of lower apertures 736 of bracket 700 are arranged at various positions along an arc, which allows the post 756 to be set at any of a group of different angles. In leg 730, the arc of lower apertures 736 extends to either side of the vertical axis. Accordingly, a ceiling panel attached to bracket 700 can be rotated to angles on either side of the vertical axis without rearranging bracket 700 on the grid beam. In other embodiments, the series of apertures are only arranged on one side of the vertical axis. In such a case, the ceiling panel can be angled in the opposite direction by securing the bracket to the grid beam in the opposite direction. Further, in some embodiments, the series of apertures have a symmetrical configuration about the vertical axis. In such a case, the selectable angles can be chosen regardless of the orientation of the bracket on the grid beam. In other embodiments, the apertures on one side of the vertical axis may be at different angles than the apertures on the other side of the vertical axis, such that intermediate angles can be selected by orienting the bracket in the opposite direction on the grid beam.
In certain embodiments of the bracket as otherwise described herein, the bracket includes a lateral projection between the support arm and the leg, and the lateral projection is configured to extend under the flange of the grid beam such that the leg is positioned below the grid beam. For example, as shown in
While the illustrated embodiment of the lateral projection is included in bracket 700, which includes a separate grid attachment structure 702 and panel attachment structure 704, in other embodiments, a lateral projection is included in bracket configurations that are formed as a single piece.
In certain embodiments of the bracket as otherwise described herein, the bracket includes a second grid attachment structure including a second support arm configured to extend over a second flange of the grid beam and a second leg extending down from the second support arm, and wherein the panel attachment structure is also removably coupled to the second grid attachment structure. For example, bracket 700 includes a second grid attachment structure 706 configured to attach to the opposite side of the grid beam. The post 756 of panel attachment structure 704 is positioned between the first grid attachment structure 702 and the second grid attachment structure 706 and is secured by fasteners 758 that extend through both grid attachment structures. As shown in
In certain embodiments of the bracket as otherwise described herein, the support arm has a width of at least ½ inch, e.g., at least 1 inch. Further, in some embodiments, the support arm has a width of no more than 8 inches, e.g., no more than 6 inches. For example, in some embodiments, the support arm has a width in a range from ½ inch to 8 inches, e.g., from 1 inch to 6 inches.
In certain embodiments of the bracket as otherwise described herein, the support arm has a depth of at least ⅛ inch, e.g., at least 3/16 inch. Further, in some embodiments, the support arm has a depth of no more than 1 inch, e.g., no more than ¾ inch. For example, in some embodiments, the support arm has a depth in a range from ⅛ inch to 1 inch, e.g., from 3/16 inch to ¾ inch. Further, in some embodiments of the ceiling system of the disclosure, the depth of the support arm is substantially the same as the outward lateral extension of the first flange of the first grid beam. For example, in some embodiments, the depth of the support arm is in a range of 1 to 1.5 times the lateral extension of the first flange of the first grid beam. For example, as shown in
In certain embodiments of the bracket as otherwise described herein, the attachment wall height is at least ½ inch, e.g., at least ¾ inch. Further, in some embodiments, the attachment wall height is no more than 3 inches, e.g., no more than 2.5 inches. For example, in some embodiments, the height of the attachment wall is in a range from ½ inch to 3 inches, e.g., from ¾ inch to 2.5 inches. Further, in some embodiments of the ceiling system of the disclosure, the height of the attachment wall is substantially the same as the height of the web of the first grid beam. For example, in some embodiments, the height of the attachment wall is in a range of 0.5 to 1.0 times the height of the web of the first grid beam. For example, as shown in
In certain embodiments of the bracket as otherwise described herein, the foot has a width of at least ½ inch, e.g., at least ¾ inch, e.g., at least 1 inch. Further, in some embodiments, the foot has a width of no more than 6 inches, e.g., no more than 5 inches, e.g., no more than 4 inches. For example, in some embodiments the foot has a width in a range from ½ inch to 6 inches, e.g., from ¾ inch to 5 inches, e.g., from 1 inch to 4 inches. Further, in some embodiments of the ceiling system of the disclosure, the width of the foot of the first bracket is substantially the same as the thickness of the first ceiling panel. For example, in some embodiments, the width of the foot is in a range of 0.5 to 1.0 times the thickness of the first ceiling panel. For example, as shown in
In certain embodiments of the bracket as otherwise described herein, the foot has a length of at least 1 inch, e.g., at least 1.5 inches. Further, in some embodiments, the foot has a length of no more than 8 inches, e.g., no more than 6 inches. For example, in some embodiments, the foot has a length in a range from 1 inch to 8 inches, e.g., from 1.5 inches to 6 inches.
In certain embodiments of the bracket as otherwise described herein, the support arm has a thickness of at least 10 thousandths of an inch, e.g., at least 20 thousandths of an inch. Further, in some embodiments, the support arm has a thickness of no more than ¼ inch, e.g., no more than ⅛ inch. For example, in some embodiments, the support arm has a thickness in a range from 10 thousandths of an inch to ¼ inch, e.g., from 20 thousandths of an inch to ⅛ inch. Further, in some embodiments, the bracket has a substantially uniform thickness. For example, in some embodiments, the bracket is formed from a plate or sheet with a single thickness. In other embodiments, different portions of the bracket have different material thickness. For example, in some embodiments, one or more of the attachment wall, support arm, leg, or foot has a greater or smaller thickness than the others.
Likewise, in some embodiments, where the bracket includes a panel attachment structure and a grid attachment structure, such as the embodiments shown in
In certain embodiments of the ceiling system as otherwise described herein, the ceiling system includes a second bracket according to the disclosure coupled to the first grid beam and a second ceiling panel, where the foot of the second bracket is attached to the second ceiling panel. For example, ceiling system 680 shown in
Likewise ceiling system 980 shown in
In certain embodiments of the ceiling system as otherwise described herein, the foot of the second bracket holds the second ceiling panel at the same angle as the first ceiling panel. For example, in ceiling system 680 and in ceiling system 980 all of the ceiling panels are oriented at the same angle. In other embodiments, the ceiling panels are arranged at different angles. For example, in some embodiments, the brackets in the ceiling system are constructed to hold the ceiling panels at different angles. Further, in some embodiments, the brackets are adjustable, and may be set so that the ceiling panels have a variety of different angles.
In certain embodiments of the ceiling system as otherwise described herein, the ceiling system includes a second grid beam and another bracket according to the disclosure coupled to the second grid beam, wherein the foot of the other bracket is attached to the first ceiling panel. For example, ceiling system 680, as shown in
In some embodiments, the other bracket has the same configuration as the first bracket. For example, in ceiling system 680 the other bracket 600C is attached to the near side of second grid beam 660B and has the same configuration as bracket 600A. In other embodiments, the brackets may have different configurations. For example, in some embodiments, the other bracket has a mirror configuration to the first bracket. For example, in some embodiments, brackets at opposing ends of the ceiling panel are configured as a mirror-image to one another so that the attachment is symmetrical over the length of the ceiling panel. For example, in some embodiments the two brackets near opposing ends of the ceiling panel both extend toward the respective ends of first ceiling panel and hold first ceiling panel at the same angle. In other embodiments, brackets used to attach a ceiling panel to different grid beams have the same configuration, and are positioned on the same side of the respective grid beams.
On the other hand, in other embodiments both brackets have the same configuration, and are positioned on the same side of the first and second grid beams so that they may hold the first ceiling panel at the same orientation. Still, in other embodiments, the brackets have a symmetrical configuration, and may hold a ceiling panel angled at either direction regardless of which side of the grid beam the bracket is attached to.
It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
Embodiment 1. A bracket configured to couple a ceiling panel to a ceiling grid, the bracket comprising:
Embodiment 2. The bracket according to embodiment 1, wherein the foot is formed as a flat plate.
Embodiment 3. The bracket according to embodiment 1 or embodiment 2, wherein the support arm is formed as a flat plate.
Embodiment 4. The bracket according to any of embodiments 1 to 3, wherein the attachment wall is formed as a flat plate.
Embodiment 5. The bracket according to any of embodiments 1 to 4, wherein the support arm and the foot are angled about a lateral axis that is perpendicular to the attachment wall.
Embodiment 6. The bracket according to any of embodiments 1 to 5, wherein the foot is laterally offset from the support arm.
Embodiment 7. The bracket according to any of embodiments 1 to 6, wherein the support arm, attachment wall, leg, and foot are formed in a single integral piece.
Embodiment 8. The bracket according to any of embodiments 1 to 7, wherein the support arm, attachment wall, leg, and foot are formed from a bent metal sheet.
Embodiment 9. The bracket according to any of embodiments 1 to 8, wherein a width of the support arm is substantially the same as a width of the attachment wall.
Embodiment 10. The bracket according to any of embodiments 1 to 9, wherein a width of the foot is substantially the same as a width of the support arm.
Embodiment 11. The bracket according to any of embodiments 1 to 10, wherein a width of the leg is less than a width of the foot.
Embodiment 12. The bracket according to any of embodiments 1 to 5, wherein the foot is coupled to the leg at a selectable angle.
Embodiment 13. The bracket according to embodiment 12, wherein the attachment wall, support arm, and leg are part of a grid attachment structure, and wherein the foot is part of a panel attachment structure that is removably coupled to the grid attachment structure so as to form the selectable angle.
Embodiment 14. The bracket according to embodiment 13, wherein the panel attachment structure includes a post extending up from the foot that is coupled to the leg of the grid attachment structure.
Embodiment 15. The bracket according to embodiment 13 or embodiment 14, wherein the leg includes a series of apertures for adjusting a position of the post so as to secure the foot at the selectable angle.
Embodiment 16. The bracket according to embodiment 15, wherein the series of apertures is arranged in an arc.
Embodiment 17. The bracket according to any of embodiments 13 to 16 wherein the bracket includes a second grid attachment structure including a second support arm configured to extend over a second flange of the grid beam and a second leg extending down from the second support arm, and wherein the panel attachment structure is also removably coupled to the second grid attachment structure.
Embodiment 18. The bracket according to any of embodiments 1 to 17, wherein the bracket includes a lateral projection between the support arm and the leg, wherein the lateral projection is configured to extend under the flange of the grid beam such that the leg is positioned below the grid beam.
Embodiment 19. The bracket according to any of embodiments 1 to 18, wherein the support arm has a width of at least ½ inch, e.g., at least 1 inch.
Embodiment 20. The bracket according to any of embodiments 1 to 19, wherein the support arm has a width of no more than 8 inches, e.g., no more than 6 inches.
Embodiment 21. The bracket according to any of embodiments 1 to 20, wherein the support arm has a depth of at least ⅛ inch, e.g., at least 3/16 inch.
Embodiment 22. The bracket according to any of embodiments 1 to 21, wherein the support arm has a depth of no more than 1 inch, e.g., no more than ¾ inch.
Embodiment 23. The bracket according to any of embodiments 1 to 22, to wherein the attachment wall height is at least ½ inch, e.g., at least ¾ inch.
Embodiment 24. The bracket according to any of embodiments 1 to 23, wherein the attachment wall height is no more than 3 inches, e.g., no more than 2.5 inches.
Embodiment 25. The bracket according to any of embodiments 1 to 24, wherein the foot has a width of at least ½ inch, e.g., at least ¾ inch, e.g., at least 1 inch.
Embodiment 26. The bracket according to any of embodiments 1 to 25, wherein the foot has a width of no more than 6 inches, e.g., no more than 5 inches, e.g., no more than 4 inches.
Embodiment 27. The bracket according to any of embodiments 1 to 26, wherein the foot has a length of at least 1 inch, e.g., at least 1.5 inches.
Embodiment 28. The bracket according to any of embodiments 1 to 27, wherein the foot has a length of no more than 8 inches, e.g., no more than 6 inches.
Embodiment 29. The bracket according to any of embodiments 1 to 28, wherein the support arm has a thickness of at least 10 thousandths of an inch, e.g., at least 20 thousandths of an inch.
Embodiment 30. The bracket according to any of embodiments 1 to 29, wherein the support arm has a thickness of no more than ⅜ inch, e.g., no more than ¼ inch.
Embodiment 31. The bracket according to any of embodiments 13 to 30, wherein a material thickness of the panel attachment structure is the same as a material thickness of the grid attachment structure.
Embodiment 32. A ceiling system comprising:
Embodiment 33. The ceiling system according to embodiment 32, wherein the attachment wall of the first bracket is secured against the web of the first grid beam.
Embodiment 34. The ceiling system according to embodiment 32 or embodiment 33, wherein at least a portion of the support arm of the first bracket is supported by the first flange of the first grid beam.
Embodiment 35. The ceiling system according to any of embodiments 32 to 34, wherein the grid beam is a T-beam.
Embodiment 36. The ceiling system according to any of embodiments 32 to 35, wherein the foot of the first bracket is secured against the first side of the first ceiling panel.
Embodiment 37. The ceiling system according to any of embodiments 32 to 36, wherein the attachment wall, support arm, and leg of the first bracket are part of a first grid attachment structure, and wherein the foot is part of a panel attachment structure that is removably coupled to the first grid attachment structure so as to form the selectable angle.
Embodiment 38. The ceiling system according to embodiment 37, wherein the bracket includes a second grid attachment structure including a second attachment wall secured to an opposite side of the web of the first grid beam, a second support arm extending over the second flange of the first grid beam, and a second leg that is removably coupled to the first grid attachment structure.
Embodiment 39. The ceiling system according to any of embodiments 32 to 38, further comprising a second bracket according to any of embodiments 1 to 31 coupled to the first grid beam; and
Embodiment 40. The ceiling system according to embodiment 39, wherein the foot of the second bracket holds the second ceiling panel at the same angle as the first ceiling panel.
Embodiment 41. The ceiling system according to any of embodiments 32 to 40, further comprising a second grid beam; and
Embodiment 42. The ceiling system according to embodiment 41, wherein the other bracket has a mirror configuration to the first bracket.
This application claims the benefit of priority of U.S. Provisional Patent Application No. 63/279,910, filed Nov. 16, 2021, which is hereby incorporated herein by reference in its entirety.
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