Patent Application
20120167515
1. Field of the Disclosure
This disclosure generally relates to ceilings in buildings and, in particular to a system, method and apparatus for a pattern on the exposed face of a ceiling suspension grid that supports ceiling panels.
2. Description of the Related Art
Ceiling suspension systems for buildings typically comprise a series of roll-formed, metallic cross members that form a grid. The grid (which has a cross-sectional shape that is typically in the form of an inverted ‘T’) is supported on hangers from the buildings' structure. Ceiling tiles are supported by the grid to complete the ceiling surface. The thin, lowermost surfaces of the grid (typically called the face or cap) are usually exposed to view between the ceiling tiles. The faces of the grid are smooth, flat and featureless, and may be color matched or coordinated with the color of the ceiling tiles. For some applications, it may be desirable to diminish the visibility or contrast of the grid with the ceiling tiles. There have been numerous attempts to accomplish this and some have met with varying degrees of success. Improvements in ceiling suspension systems continue to be of interest.
Embodiments of a system, method and apparatus for a ceiling system comprise support members that are interconnected to form a ceiling suspension. The ceiling suspension is suspended from a building structure. Each of the support members has exposed surfaces, such as facing or capping, that are patterned and different in textural appearance than other portions of the support members to define patterned surfaces.
For example, the patterned surfaces may have non-smooth textures that are uniform and symmetrical, or non-uniform and irregular. The patterned surfaces may have features such as lines, slots, dimples, protrusions, peaks and valleys and cross-hatching, which may be formed on capping on the support members. In other embodiments, other surfaces may be patterned like the patterned surfaces, such as for cloud perimeter trim.
The foregoing and other objects and advantages of these embodiments will be apparent to those of ordinary skill in the art in view of the following detailed description, taken in conjunction with the appended claims and the accompanying drawings.
So that the manner in which the features and advantages of the embodiments are attained and can be understood in more detail, a more particular description may be had by reference to the embodiments thereof that are illustrated in the appended drawings. However, the drawings illustrate only some embodiments and therefore are not to be considered limiting in scope as there may be other equally effective embodiments.
The use of the same reference symbols in different drawings indicates similar or identical items.
The metal raw materials (e.g., steel, aluminum, etc.) used in the roll-forming process arrives at the plant in coils. This material is about several inches wide, and about 0.012 to 0.020 inches thick, depending on the load rating desired from the finished grid product. For some applications, the steel is about 0.015 inches thick. The coils are unwound into a roll forming machine, which comprises a series of roll sets that progressively bend or fold the metal into the final shape desired. Each roll set represents a “step” in the process of roll-forming. Depending on the complexity of the finished shape, the number of roll sets can be as few as two or three (such as for forming a rain gutter), to as many as needed. For ceiling suspension t-bar type grids, the number of roll sets is generally about 16. A capping material, which also arrives at the plant in coils that are typically about 1 1/16 inches for a 1 5/16 inch-wide grid, is introduced at one of the later roll sets. This material can be steel or aluminum and is generally white, but could be any color. This material is crimped tightly onto the t-bar shape, which is formed continuously. A shear cuts the finished shape into pieces of the length desired. In the case of main runners, this is about 12 feet. Cross tees are commonly four feet and two feet in length, but can be custom made to any length. The slots, holes, and end joinery are all added later in the process in a press.
The support members for the ceiling system interconnect to form a ceiling suspension. The ceiling suspension may be suspended with wires or hangers 27 from a roof or floor support structure (not shown) in a building. The main runners 23, cross tees 25 and wall angle 26 may be substantially perpendicular, such that the ceiling suspension forms a grid for supporting ceiling tiles 29, as is known by those of ordinary skill in the art. A plurality of the ceiling tiles 29 is supported by the ceiling suspension to form a more aesthetically appealing ceiling beneath the usually less appealing exposed structure of a building.
There have been some attempts to change the appearance of grids to occupants in buildings. For example, some grids have been painted with irregular, non-symmetric features in an attempt to blend in with the ceiling tiles. Other attempts have included a fine grit in the paint used to color the grid to change the appearance of the grid to more of a matte finish. These designs were aesthetically unappealing and unsuccessful.
Referring now to
The patterned lower surfaces 31 of the support members may comprise many different appearances and/or textures. For example, the patterned lower surfaces may be two-dimensional (e.g., printed) or three-dimensional, and may comprise non-smooth textures. The patterned lower surfaces may have features that are uniform and symmetrical (e.g., in two or three-dimensional configurations), non-uniform and irregular (e.g., in three-dimensional configurations), or a combination thereof.
The features used to form the different textural appearance may be roll-formed, stamped, embossed, machined or otherwise mechanically formed in the support members. A three-dimensional pattern may be impressed into the thin capping material, then secured on the lower ends of the t-bar shapes of the runners and cross tees, on wall angles, and on surfaces of cloud perimeter trim. In other embodiments, the features are painted, imaged or printed directly on these types of support members, or similarly placed on a flexible adhesive tape that is attached to the support members.
The metal raw materials (e.g., steel, aluminum, etc.) used in the roll-forming process arrives at the plant in coils. This material is about several inches wide, and about 0.012 to 0.020 inches thick, depending on the load rating desired from the finished grid product. For some applications, the steel is about 0.015 inches thick. The coils are unwound into a roll forming machine, which comprises a series of roll sets that progressively bend or fold the metal into the final shape desired. Each roll set represents a “step” in the process of roll-forming. Depending on the complexity of the finished shape, the number of roll sets can be as few as two or three (such as for forming a rain gutter), to as many as needed. For ceiling suspension t-bar type grids, the number of roll sets is generally about 16. The capping material, which also arrives at the plant in coils that are typically about 1 1/16 inches or 15/16 inches wide, is introduced at one of the later roll sets. This material can be steel or aluminum and is generally white, but could be any color. This material is crimped tightly onto the t-bar shape, which is formed continuously. A shear cuts the finished shape into pieces of the length desired. In the case of main runners, this is about 12 feet. Cross tees are commonly four feet and two feet in length, but can be custom made to any length. The slots, holes, and end joinery are all added later in the process in a press.
Other embodiments of the patterned lower surfaces may include lines 41 (see, e.g.,
As depicted in some of the drawings (e.g.,
As shown in
In other embodiments (
This written description uses examples to disclose the embodiments, including the best mode, and also to enable those of ordinary skill in the art to make and use the embodiments. The patentable scope is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. The order in which activities are listed are not necessarily the order in which they are performed.
In the foregoing specification, the concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the embodiments as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the embodiments.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Also, the use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of scope. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
After reading the specification, skilled artisans will appreciate that certain features are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, references to values stated in ranges include each and every value within that range.
This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/428,267, filed Dec. 30, 2010, and is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61428267 | Dec 2010 | US |
