System, method and apparatus for patterned ceiling suspension

A ceiling suspension system has support members that are interconnected to support ceiling panels. The ceiling suspension system is suspended from a building. Each of the support members has a lower surface that is patterned and different in textural appearance than other portions of the support members to define patterned lower surfaces. For example, the patterned lower surfaces may have non-smooth textures that are uniform and symmetrical, or non-uniform and irregular. The patterned lower surfaces may have three-dimensional features such as lines, slots, dimples, protrusions, peaks and valleys and/or cross-hatching, which may be roll-formed on capping on the support members.

BACKGROUND

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.

SUMMARY

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.

DETAILED DESCRIPTION

FIGS. 1-9disclose embodiments of a system, method and apparatus for a ceiling system. For example, as shown in the schematic drawing ofFIG. 1, a ceiling system21may comprise a plurality of support members. The support members may be configured in many forms, such as main beams or runners23, cross tees25and wall angle26. The support members may be suitably roll-formed steel or aluminum, extruded aluminum, plastic, or fiber-reinforced plastic (FRP), depending on the application.

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 hangers27from a roof or floor support structure (not shown) in a building. The main runners23, cross tees25and wall angle26may be substantially perpendicular, such that the ceiling suspension forms a grid for supporting ceiling tiles29, as is known by those of ordinary skill in the art. A plurality of the ceiling tiles29is 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 toFIGS. 1-3, each of the support members, such as main runners23, cross tees25and wall angle26, has a lower surface31that is patterned and different in textural appearance than other portions of the support members to define patterned lower surfaces31. For example, the other portions of main runner23may comprise its bulb33, web35and/or flange37. The patterned lower surfaces31may comprise the lowermost surfaces of the support members. In some embodiments, the patterned lowermost surfaces31are located beneath a lowest portion of the ceiling tiles29, as shown inFIG. 2.

The patterned lower surfaces31of 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.

As depicted in some of the drawings (e.g.,FIGS. 4-6and8), the features of the three-dimensional embodiments may protrude or recede from a reference plane “r” by a distance “d.” For example, if the features protrude outward (i.e., downward) from the support members, the reference plane r is defined as the mean plane from which the protrusions extend. If the features protrude inward (i.e., upward) from the support members, the reference plane r is defined as the mean plane from which the recessions recede. In some embodiments, the distance d may comprise about 0.015 to 0.250 inches, about 0.031 to 0.125 inches, or about 0.031 to 0.0625 inches.

As shown inFIG. 8, the patterned lower surfaces31may be located and/or formed on capping51that is secured to lower ends of the support members, as is known to those of ordinary skill in the art. For example, the capping51may comprise a thickness of about 0.008 to 0.009 inches. The capping51may be patterned and different in textural appearance from the other portions of the support members, as described herein. The capping may comprise plastic or metallic materials.

In other embodiments (FIG. 9), at least some of the support members further comprise other non-horizontal surfaces61that are patterned like the patterned lower surfaces31. In some versions, these other surfaces61may be referred to as “cloud perimeter trim.” The other surfaces61may comprise out-of-plane, vertical, or substantially perpendicular structures to the patterned lower surfaces31.

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.

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.