This invention relates to suspended ceiling systems and more particularly to ceiling tiles/panels that typically lay-in an exposed suspended ceiling grid or lattice.
The grid profile can vary from the standard inverted-T design in various exposed face widths, to more complicated bolt-slot (‘reveal’) and channel profile (‘bandraster’) profiles. Any grid profile with (most likely horizontal, or near-horizontal) flanges on which the outer edges of lay-in tiles/panels are supported will accommodate the use of this invention.
Above the array in the plenum are located electrical and computer wiring, ventilation equipment and duct work, lighting systems, sound systems and an array of other mechanical systems. Suspended ceilings have the advantage of hiding all of these mechanical and electrical components.
Typical appropriate, light-weight tile/panel compositions include; but are not limited to, vitreous fibers, natural organic fibers, plastic resins, solid metals and metal alloys, perforated metals and metal alloys, expanded metals and metal alloys, woven and welded wire fabrics, cast minerals, gypsum and all the possible mixtures, combinations, and laminations of the above materials.
Once the grid profile has been hung from the structural ceiling by metal straps, threaded rods or wires, the tiles are removed from their group packaging and one by one are lifted through a rectangular grid opening at an angle and then are lowered substantially flat so that their edges catch and lay on the inwardly extending flanges of the grid.
From time to time maintenance work must be performed above the suspended ceiling within the plenum. When a maintenance person needs to access the plenum area above a suspended ceiling, either the lay-in ceiling tiles/panels are pushed up into the ceiling and laid on top of another area of ceiling grid, or the tiles/panels must be removed from the ceiling and brought down to the lift platform, scaffolding, floor, tabletop, or other surface for temporary storage. In either case, the ceiling tiles/panels can be easily damaged in the process of removal. Tiles that are pushed into the ceiling plenum can be marred or scratched by being slid across the grid, or across light fixtures, smoke alarms, and other mechanical or electrical items attached to other tiles. Plus when the removed tile is placed on top of other panels and the previously listed items, the lower aesthetic surface of the removed tile may become soiled by the dust and dirt that collects on the upper surface of these other suspended ceiling components. Also, the edges of tiles can become damaged by accidentally being slid into grid hanger wires, threaded suspension rods, or other sharp objects within the plenum.
Tiles that are removed from the ceiling and brought down to a lower surface for temporary storage can be damaged during handling, both during removal and re-installation. The tiles can be scraped or scratched when passing through the grid opening. They can be bumped against ladders or lifts, and they can be accidentally dropped during this removal and transfer process. Once placed in a temporary storage location, the tiles are subject to multiple sources of potential damage: personnel and machinery could run into them; liquids could be spilled, dripped on them, or flood the surface on which they are placed. The surface on which the tiles are placed could be dirty and/or oily and could transfer directly to the aesthetic, visible surfaces of the tiles or could be transferred during subsequent handling. If placed in an upright position, on edge, the tiles could fall over or slide down onto the floor and be walked on or run over by vehicles.
Also, the process of removing tiles temporarily and placing them somewhere in the area below the ceiling, and then re-installing these same panels sometime later requires a great deal of time to accomplish.
A ceiling tile with two pairs of outer straight opposing edges for a suspended ceiling having a grid with an opening with two pairs of near-horizontal opposing flanges on which the outer edges of the tile are supported. Two opposing notches on one of the pair of edges receive and rest upon one of the pairs of opposing flanges to vertically hang the ceiling tile.
A principal object, advantage and feature of the self-hanging notched ceiling tile is that the notch is designed to support the ceiling tile in a vertical orientation on the horizontal flanges of the grid profile when the ceiling tile/panel is relocated from its normal lay-in horizontal location in order to gain access to the plenum space above the suspended ceiling.
Another object and advantage of the notched tile is that multiples of the notched tile maybe deliberately hung in a vertical orientation from the grid in a ‘baffle’ arrangement with an ‘open-plenum’ ceiling design for absorption of undesirable room noises to create a more quite environment.
Another object and advantage of the notched tile is that the feature can be employed in any composition of ceiling tile that is strong enough that the tile can be supported only along its' outer edges (by notches) without damage or failure because the tile is stiff enough that the panel will not excessively deflect or slip off the flange on the grid.
Another object and advantage of the notched tile is that the pair of notches are located close to the upper edge of the vertically hung tile. By this arrangement, the upper portion of the tile does not extend beyond the upper limits of grid profile into the plenum space.
Another object and advantage of the notched tile, which can easily be hung from the ceiling grid, is that it will greatly reduce the potential for overall damage and soiling of the visible aesthetic surface of the notched tile.
Another object and advantage of the notched tile is the significant time savings in the reduced time involved to temporarily hang the tiles from the grid. This hanging time is much less than removing them to a temporary storage location below the ceiling and to place the tiles away from the actual working area. When hanging the tile by its notches, the aesthetic surface is faced away from the worker.
Referring to
The ceiling tile 20 typically is square edged or tegular with a lowered plane rendering a sculptured appearance. The ceiling tile 20 has a first pair of outer straight opposing edges 22 and a second pair of outer straight opposing edges 24. These edges 22 and 24 rest upon the flanges 14 of the grid 8 to support the ceiling panels 20 in an installed fashion. The ceiling panels have a lower aesthetic face or surface 26 and an upper plenum face or surface 28 that is generally unfinished. However, both faces 26 and 28 may be finished when the ceiling tiles 20 are desired to be suspended vertically to create a more open plenum 4 and to create sound baffles.
As more clearly seen in
The Notch 20 feature suitably may be created by employing a ‘hauncher’, which is a machine normally used in the woodworking industry to produce complicated two-dimensional profiles (shaped cuts) along the edges of boards or panels. The hauncher employs a rotating tool with the shape of the feature profile much like a large router bit. The rotating tool can move through the stationary tiles 20, or the tiles 20 can move past the stationary rotating tool. Haunchers are available from Progressive Systems, Inc. of Anoka, Minn. The notch 20 could also be fabricated by various methods including; but not limited to, punching, jig-sawing, routing, water jet cutting, laser cutting or with a hand punch tool. The specific fabrication method of the notch 20 is often based on the mechanical properties of the tile 20 composition being cut.
Installation of the ceiling tiles 20 of the present invention is standard in the industry. After the grid 8 has be securely suspended by hangers 6, the installer removes tiles 20 from their packaging and lifts each tile 20 through an opening 10 at an angle as to clear and not touch the grid flanges 14. The tile 20 is lowered substantially horizontally so that edges 22 and 24 come to rest upon flanges 14 of the grid 8.
Based on the required size and location of the notches 32 on the particular tile 20 and the mechanical properties and composition of the tile 20, the notches 20 may require different shapes as shown in
The physical design of the notch is to be shaped such that when the tile 20 is hanging vertically between two parallel flange sections 14 of ceiling grid 8, the upper notch wall 34, closest to the upper edge of the tile, is shaped to conform to the upper surface of the grid flange 14 which the notch rests upon. For most cases this upper notch wall 34 will be horizontal; however, special grid profiles may require other shapes.
Again, mechanical properties and composition of the tile 40, may require the notches 42 to have some reinforcement 48. Possible reinforcements 48 in the notch 40 might include; but are not limited to, extra-heavy coatings of paint; coatings of epoxy or other liquids that harden into strong, tough surfaces; flat adhesive liner sheets (‘patches’) on the rear, unexposed surface of the tile 40 in the area surrounding the notch 42. The reinforcement liner material 48 could be paperboard, plastic, or metal sheets; rods, pins, or small bars of metal or plastic driven into the edge material of the tile 40 just above the notch 42; three-dimensional notch inserts/liners that fit into the notch and provide a strong, solid surface. These inserts/liners 48 could be formed, molded, or cast, they could be metal or plastic, the insert 48 could be held in place with adhesive or mechanical barbs. The inner notch wall 46 must be vertical and long enough to provide some clearance for ease of installation when hanging the tile 40 vertically. The distance between the vertical walls 46 of each side-to-side pair of notches 42 must be precisely maintained to minimize the visibility of the notches 42 when the tile 40 is installed in its normal lay-in position on the grid flanges 14. The optional notch third wall below the vertical wall 46 can be straight or curved as they connect back to the outer vertical edge of the tile 40. A rectangular notch is the simplest shape; however custom notches might be required for special grid profiles or to aid installation when the tile/panel is being hung vertically.
The above embodiments are for illustrative purposes only. Various other embodiments of the present invention may be contemplated. The true scope of the present invention is described in the following claims.
This application is a Continuation-in-part of Design patent application Ser. Nos. 29/394,417 and 29/394,422 both filed on Jun. 16, 2011 respectively for Self-Hanging Tegular Notched Ceiling Tile and Self-Hanging Square Edge Notched Ceiling Tile.
Number | Date | Country | |
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Parent | 29394417 | Jun 2011 | US |
Child | 13367537 | US | |
Parent | 29394422 | Jun 2011 | US |
Child | 29394417 | US |