The present invention relates to suspended ceiling systems, and in particular, to a ceiling panel having an enlarged perimeter flange for securement beneath a “T” bar grid system, and a particular structure of the ceiling panel.
“T” bar ceiling systems are extremely well known and are primarily used for receiving a fiber type ceiling panel that is supported above outwardly extending flanges of the “T” bar grid system. With this arrangement, the bottom flange of the “T” bar grid components is visible from below and forms part of the finished ceiling surface. In most cases the ceiling panels are generally planar and located above the bottom flange. In some “T” bar ceiling systems the acoustical panels may be contoured and partially extend below the “T” bar grid system while still supported at the perimeter edge by the “T” bar grid members. This type of arrangement reduces the visual effect of the exposed “T” bars but the lower flanges continue to be visible.
It is also known to use a “T” bar grid system for suspending ceiling panels below the grid system such that the ceiling panels hide the “T” bar grid network (concealed “T” bar ceiling system). In these systems the upper edge of the ceiling panels engage the lower flange of the “T” bar grid network. Torsion springs or other securing arrangements suspend the ceiling panels beneath the “T” bar grid system.
A lift and shift “T” bar grid ceiling panel system is known that suspends ceiling panels beneath a “T” bar grid network. In some lift and shift grid ceiling panel systems a portion of the grid network is exposed and forms part of the finished ceiling system. Other lift and shift ceiling panel systems are designed to overlap substantially on the lower surface with the “T” bar members thus hiding the grid network. In this type of system the acoustical panel is oversized relative to the cells of the grid network. The ceiling panels are secured to the grid network by initially suspending one edge of a panel and shifting it over relative to the grid network. The panel may then be moved to the horizontal position and shifted in the opposite direction to suspend the opposite edge of the ceiling panel.
Although these systems in theory provide an accurate ceiling (little variation in the plane of the ceiling), the known lift and shift systems locate the ceiling panels below the grid network and the suspension clips of each panel are mounted on a top surface of the panel. To avoid or reduce possible damage the suspension clips are secured to the panels on site by the installer. This is a time consuming process and introduces a further variable that may affect the quality of the ceiling system.
The present invention seeks to overcome a number of manufacturing issues with respect to lift and shift suspended ceiling systems, and also provides a system which is convenient to install.
A ceiling panel according to the present invention comprises a perimeter frame, an acoustical insert secured within the perimeter frame, and positioned to be inwardly offset to a side edge of the ceiling panel. A finished surface substrate is secured beneath and covers a lower surface of the perimeter frame and the acoustical insert material. The perimeter frame comprises a series of connected extruded members where each extruded member includes an outwardly extending flange defining a wide border edge of the ceiling panel and an integral vertical section to one side of the flange. The outwardly extending flange and the integral vertical section collectively form a stepped side edge of the ceiling panel. The finished surface substrate is secured to the outwardly extending flange of each extruded member and the vertical section of each extruded member is held in abutting contact with a side edge of the acoustical insert.
In a preferred aspect of the invention, each extruded member includes in cross section at least one securing flange extending inwardly from the vertical section and located at an end of the vertical section opposite the outwardly extending flange or at an intermediate position on the vertical section.
In yet a further aspect of the invention each extruded member includes two inwardly extending securing flanges positioned in a non-aligned manner with the outwardly extending flange.
In yet a further aspect of the invention one of the inwardly extending flanges overlies a top edge of the acoustical insert.
In a different aspect of the invention one of the inwardly extending flanges is received and projects into a side edge of the acoustical insert.
In a preferred aspect of the invention a top surface of each outwardly extending flange includes a low profile securing channel extending in a length of the extruded member. Preferably gusset securing brackets are provided where each gusset securing bracket is received in the low profile securing channels of abutting extruded members with these gusset securing brackets connecting abutting extruded members.
In a further aspect of the invention, each gusset securing bracket is generally an L-shaped stamped plate with at least one upwardly and forwardly extending securing tab defining a securing gap below said securing tab for supporting said ceiling panel from a “T” bar grid.
In yet a further aspect of the invention each gusset securing bracket includes a first flat arm without any significant protrusions on an upper surface thereof and a second flat arm having at least one upwardly extending securing tab with a horizontal extending segment.
In yet a further aspect of the invention the outwardly extending flange of each extruded member includes on a bottom surface thereof a series of longitudinally extending shallow ribs of progressively decreasing height from the vertical section to the perimeter of the ceiling panel. Preferably these series of shallow ribs include at least three shallow ribs.
In yet a further aspect of the invention the ceiling panels are preferably rectangular in shape with gusset securing brackets provided in each corner of the rectangular shaped ceiling panel.
Preferred embodiments of the invention are shown in the drawings, wherein:
The suspended ceiling system 2 includes the “T” bar support grid 4 with a series of suspended ceiling panels 6 secured to the underside of the support grid. The support grid includes main T-members 8 and cross T-members 10. Also shown in
The “T” bar support grid generally shown as 4 is extensively used in ceiling systems, is relatively inexpensive and is well known to a host of installers.
During installation, the main “T”-members 8 are appropriately suspended beneath an unfinished ceiling.
Once the main “T”-members 8 have been located, cross “T”-members 10 are mechanically connected to the main “T”-members 8. There are a number of different “T” bar grid systems, but these systems all work in a similar manner. Although care is taken to accurately position the grid network, some variation occurs, particularly with respect to the position of the cross “T”-members 10.
The ceiling panels shown in the figures are referred to as lift and shift ceiling panels. In this case, the particular securing mechanism allows the panels to be shifted in one direction typically towards a main “T”-member 8 and subsequently the panel is pivoted upwardly to the horizontal position and shifted in the opposite direction to engage a further “T”-member. Although the preferred arrangement is to support the panel on the main “T”-members 8, it can be appreciated that support the panel on the cross “T”-members 10 is also possible. There is a slight gap between adjacent panels that is preferably kept to a minimum to hide the “T” bar grid network
In contrast to existing lift and shift suspended ceiling systems, the present ceiling panels include a wide outwardly extending flange defining a wide border area about the ceiling panel. This aspect can be appreciated from a review of
Each ceiling panel includes an outwardly extending perimeter flange 36 which is of a thin profile with the body of the ceiling panel including the acoustical dampening material 40 located interior to this flange. Preferably, this perimeter flange is defined by an extrusion member 60 and the upper surface of the perimeter flange 36 includes a securing channel 64 for receiving gusset clips 20. In this way the gusset clips 20 are associated with the lower surface of the ceiling panel and is only separated from this lower surface by the thickness of the perimeter flange. A large portion of the ceiling panel including the acoustical dampening material is located above the bottom flange of the “T” bar grid support network as shown in the view of
The large perimeter flange about the ceiling panel with the inwardly offset acoustical dampening material allows for the lift and shift installation of panels in combination with the perimeter flange, gusset clips and “T” bar grid defining the finished level of the ceiling panels.
As shown in the perspective view of
The extrusion member 60 includes vertical section 70 extending upwardly from the outwardly extending flange 62 and this vertical section acts as a frame about and in engagement with the acoustical material 40 of the ceiling panel. The vertical section 70 includes a top inwardly directed flange 72 that overlies the top surface of the acoustical dampening material 40 and an intermediate securing flange 74 that is inserted into the acoustical dampening material. Depending upon the particular acoustical dampening material, this intermediate securing flange is preferably received in a slot of the dampening material and has a slight interference fit therewith. Typically the securing flange includes a ribbed surface and an adhesive can also be used to improve securement.
As shown in
A further benefit of the ceiling system is shown in
The present system advantageously uses the “T” bar grid support network that is widely available and relatively cost effective to use. Improved accuracy of a lift and shift ceiling system is provided beneath the “T” bar grid network by using extrusion members with a wide perimeter flange about the ceiling panels. This perimeter flange is essentially immediately below the lower flange of the “T” bar support network. The securing of the ceiling panel beneath the “T” bar grid network is achieved by using stamped gusset clips preferably that are received in channels of the extrusion members. These gusset clips can only secure the extrusion members about the body of the acoustical ceiling panel, but they also accurately define the suspension points. A substantial portion of the ceiling panel is above the lower flange of the “T” bar grid network where tolerance variations in the thickness of the overall ceiling panel are not transmitted to the finished surface.
The ceiling panels also include a wide perimeter flange about the ceiling panels and this is defined by the extrusion members used to define this edge. These extrusion members include an outwardly extending flange which on the lower surface preferably includes a series of ribs. These ribs are used to assist in the adhesive securement of a finishing substrate while providing a transition between the acoustical dampening material and the edge of the ceiling panels. This blends any variations and hides the outer perimeter frame.
The modified gusset clip 120 of
The modified gusset clip 120 also includes the locating notch 30 on the securing tab 122 and this does provide alignment and accurate positioning beneath the “T” bar grid. As shown in
The modified gusset clip 120 of
A further feature of the modified gusset clip is the securing port 140. In some cases if a panel is used adjacent a wall or due to particular circumstances it may be desirable to secure the panel by means of the port 140. Typically this port is not used but there may be circumstances where it is preferable to provide support through this component.
Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.
Number | Date | Country | Kind |
---|---|---|---|
2706034 | Jun 2010 | CA | national |