Ceiling tile with integrated lighting and ceiling system

The present disclosure relates generally to a ceiling tile, for example, suitable for use in a ceiling grid. The present disclosure relates more particularly to a ceiling tile including a light housing extending across a first portion of a width of the ceiling tile, and a panel extending across a remaining portion of the width of the ceiling tile.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The present disclosure relates generally to ceiling tiles, for example, suitable for placement in a ceiling grid. The present disclosure relates more particularly to a ceiling tile with an integrated light.

2. Technical Background

Ceiling tiles provide a practical and cost effective structure for constructing ceilings. The ceiling can be maintained easily by replacing old or damaged ceiling tiles, and any maintenance that is needed within the ceiling can be easily completed by temporarily removing one or more tiles. While the replacement of an entire ceiling tile with a similarly shaped lighting fixture is known, consumer preference mandates the availability of a variety of different lighting structures in tiled ceilings.

One lighting structure that is attractive and well-liked by consumers is linear lighting. In particular, linear lighting that spans a length that is longer than one ceiling tile is popular. To provide such lighting, contractors who are building a ceiling grid that will hold the ceiling tiles will incorporate a linear lighting structure into the grid itself. In other words, beams of the ceiling grid are constructed to surround the linear lighting structure, and the adjacent ceiling tiles are either cut down to size or shifted over to accommodate the linear light. The process of building additional grid to accommodate the linear light is time consuming and costly. Moreover, once the linear lighting is built into the ceiling grid, adjusting the lighting to accommodate new design preferences requires rebuilding the ceiling grid, which is nontrivial. The present inventors have recognized that a more convenient and flexible way to provide lighting in ceiling systems, including linear lighting, would be advantageous and attractive to builders.

SUMMARY OF THE DISCLOSURE

In one aspect, the present disclosure provides a ceiling tile comprising:a light housing extending across a first portion of a width of the ceiling tile; anda panel extending across a remaining portion of the width of the ceiling tile.

In another aspect, the disclosure provides a ceiling system comprising:a ceiling grid including a plurality of beams defining a plane of the ceiling;a plurality of first ceiling tiles supported by the ceiling grid; andone or more second ceiling tiles including:a light housing extending across a first portion of a width of the ceiling tile, anda panel extending across a remaining portion of the width of the second ceiling tile.

In another aspect, the disclosure provides a method of installing ceiling tiles in a ceiling, the method comprising:providing a ceiling grid including a plurality of beams defining a plane and arranged to provide a plurality of openings for ceiling tiles;placing a plurality of first ceiling tiles in a first portion of the openings; andplacing one or more second ceiling tiles in at least one other opening in the ceiling grid so as to form a ceiling system comprising:the ceiling grid;the plurality of first ceiling tiles supported by the ceiling grid; andthe one or more second ceiling tiles, each of the second ceiling tiles including:a light housing extending across a first portion of a width of the ceiling tile, anda panel extending across a remaining portion of the width of the ceiling tile.

In another aspect, the disclosure provides a method of installing ceiling tiles in a ceiling, the method comprising:providing a ceiling grid including a plurality of beams defining a plane and arranged to provide a plurality of openings for ceiling tiles;placing a first ceiling tile in a first opening in the ceiling grid; andplacing a second ceiling tile in a second opening in the ceiling grid, the second ceiling tile including:a light housing extending across a first portion of a width of the ceiling tile, anda panel extending across a remaining portion of the width of the ceiling tile.

Additional aspects of the disclosure will be evident from the disclosure herein.

DETAILED DESCRIPTION

As described above, the present inventors have noted that conventional lighting in a ceiling grid is costly and time consuming to construct. Further, modifying the lighting once constructed is also costly and time consuming. The present inventors have developed a ceiling tile that provides lighting that is more efficient and easier to construct and modify.

Accordingly, one aspect of the disclosure is a ceiling tile including a light housing extending across a first portion of a width of the ceiling tile, and a panel extending across a remaining portion of the width of the ceiling tile. Such a ceiling tile is shown inFIGS. 1A to 1D. Ceiling tile100includes a light housing120and a panel150. As a whole, ceiling tile100has a width102and a breadth104(shown inFIG. 1B). The light housing120extends across a first portion106of the width102of ceiling tile100. Light housing120also extends across the entire breadth104of ceiling tile100. In use, light housing120provides a linear presentation of light into a room in which ceiling tile100is installed. For example, the light housing120reflects light from a light source170in the form of a strip of light emitting diodes (LEDs) to an area below the ceiling tile. Panel150has some overlap with light housing120and extends into the first portion106of the width102of the tile, but also extends across the remaining portion108of the width102of ceiling tile100. Similar to light housing120, panel150also extends across the entire breadth104of ceiling tile100.

The light in ceiling tile100is integrated into the tile such that construction of areas of the ceiling that include the lighting can be completed in much the same way that the areas of the ceiling that include conventional ceiling tiles are constructed. Once the ceiling grid is assembled, ceiling tile100with the integrated lighting can be placed into an opening in the grid to form a section of the ceiling with integrated lighting. Thus, ceiling tile100allows for the construction of lighting without any specialized placement of the ceiling grid beams or any added beams.

The integral construction of the light into ceiling tile100is accomplished by the attachment of the light housing120to the panel150of the tile. As the person of ordinary skill in the art will appreciate, the connection between the light housing and the panel can be accomplished in a variety of different ways. For example, the light housing may be attached to the panel using adhesive or fasteners. Other common methods are also possible.

In certain embodiments as otherwise described herein, the light housing is a linear light housing. The linear light housing extends across at least a portion of the ceiling tile and presents a linear representation of light into the space being illuminated. For example, the light housing in ceiling tile100is a linear light housing120and extends across the entire breadth of the ceiling tile100. Accordingly, linear light housing120presents a line of light that spans the entire breadth of the tile100.

In certain embodiments as otherwise described herein, the light housing extends across the first portion of the width of the ceiling tile from a first edge of the ceiling tile. For example, light housing120extends across the first portion106of ceiling tile100from edge110. Accordingly, the side of ceiling tile closest to edge110is entirely formed by lighting housing100. In other embodiments the portion of the width of the ceiling tile that the lighting housing extends across is spaced from the corresponding edges.

In certain embodiments as otherwise described herein, the light housing is non-linear. For example, ceiling tile200, shown inFIGS. 2A and 2B, includes a circular light housing220. The circular light housing220extends across a first portion of the width of the ceiling tile that is located at the center of the ceiling tile. Accordingly, the panel250, extends across the remaining portion of the width of the ceiling tile on either side of the light housing220. A light source in the form of a ring of LEDs shines light up onto a dome-shaped reflector280that shines light down into the space below ceiling tile200. The ring of LEDs is disposed above panel250, and is therefore hidden when viewed from below.

Ceiling tile300, shown inFIGS. 3A and 3Balso depicts a non-linear lighting housing. Specifically, lighting housing320is in the shape of an arc, and panel sections350are disposed on both sides of lighting housing320. The light source in ceiling tile300is provided by a strip of LEDs that is arranged in a curve within light housing320following the curve of the arc. The strip of LEDs is disposed above one of the panel sections350and is therefore obscured from view when looking up at the tile300.

In certain embodiments as otherwise described herein, the panel includes a body having a planar surface. In certain embodiments, the planar surface is parallel to the plane of the ceiling. For example, ceiling tile100includes a panel having a body152that has a planar surface154. The planar surface154is arranged to be parallel to a plane of the ceiling115when ceiling tile100is installed in the ceiling. In other embodiments, the panel includes a planar surface that is at an angle to the plane of the ceiling. For example, in some embodiments the planar surface of the panel is at an angle of no more than 30 degrees from the plane of the ceiling, e.g., no more than 20 degrees from the plane of the ceiling, e.g., no more than 10 degrees from the plane of the ceiling, e.g., no more than 5 degrees from the plane of the ceiling, such as 3 or 4 degrees. For example ceiling tile400includes a panel450with a body452that includes planar surface454. The planar surface454is disposed at a slight angle with respect to the plane of the ceiling415.

In certain embodiments as otherwise described herein, the ceiling tile further includes a contact surface disposed around a perimeter of the ceiling tile, where the contact surface defines the plane of the ceiling. In certain embodiments, the contact surface includes an outer edge of the light housing. Further, in certain embodiments, the contact surface includes a portion of the planar surface of the panel. For example, ceiling tile100includes a contact surface130that serves to support ceiling tile100on the structural members of a ceiling grid or other support surface. The use of contact surface130to support ceiling tile100is shown inFIG. 1D, where ceiling tile100is being supported by two T-beams of a ceiling grid along the contact surface130of the tile. Contact surface130is disposed around the outer perimeter132of the tile and includes both an outer edge134of linear light housing120and also an outer portion of the planar surface154of panel150. In particular, contact surface130includes a portion of planar surface154that includes a section near edge111of the ceiling tile and sections along the opposing side edges112,113that run across the width of the tile (shown inFIG. 1B). Because contact surface130of ceiling tile100is supported by elements of a ceiling grid, the contact surface130defines the plane115of the ceiling in which ceiling tile100is installed.

In certain embodiments as otherwise described herein, the contact surface includes a lower surface of a projection extending from an outer edge of the panel. For example, ceiling tile500, shown inFIG. 5, includes a projection536that extends outward at the outer edge of panel550. The projection536forms a portion of the contact surface530that supports ceiling tile500on the T-beams of the ceiling grid. The contact surface530of ceiling tile500also includes the outer edge534of the light housing520. While the cross-sectional view inFIG. 5only shows the projection536at edge511, it should be understood that panel550includes the projection536along the side edges of tile500as well. Of course it is also possible to restrict the projection to only certain areas of the outer edge of the panel. The projection536of ceiling tile500is not included on the inside edge of the panel550adjacent to the light housing520. However, in certain embodiments, the projection extends around the entire perimeter of the panel.

In certain embodiments as otherwise described herein, the ceiling tile further includes at least one clip attached to the panel, and the contact surface includes a surface of the at least one clip. For example, ceiling tile600, depicted inFIG. 6, includes clip638attached to panel650. Clip638extends outward from an outer edge of panel650and provides a surface639that is supportable by the T-beam of the ceiling grid. As a result, surface639forms a portion of the contact surface630of ceiling tile600, which also includes outer edge634of the linear light housing620. Clip638is attached to ceiling tile600by friction resulting from the clip being inserted into the body652of panel650. In other embodiments the clip is attached to the panel using an adhesive or a separate fastener. The depicted cross section of ceiling tile600only shows one clip638at outer edge611. However, ceiling tile600also includes a second clip along outer edge611for stability. In other embodiments, clips are also included along the side edges of the ceiling tile, where these additional clips also form portions of the contact surface. The use of clip638allows the panel650of tile600to include an outward flange653that obscures a portion of the ceiling grid.

In certain embodiments as otherwise described herein, the ceiling tile is rectangular. For example, ceiling tile100, shown inFIGS. 1A to 1D, is rectangular with a width102and a breadth104that are equal in length (and thus, ceiling tile100is a square). The width102of ceiling tile100extends from edge110to edge111and the breadth104extends from edge112to edge113. In other embodiments, the ceiling tile has other shapes, such other polygons or closed curves. For example, one embodiment of a ceiling tile is a triangle where the linear light housing extends along one edge. In such an embodiment, where the shape has an odd number of sides, the width of the tile extends from one edge to an opposing point of the ceiling tile. Of course, other shapes such as pentagons, hexagons, octagons, circles, ellipses and ovals are also possible.

In certain embodiments as otherwise described herein, the width of the ceiling tile is in a range of 20 to 30 inches, e.g., 23 to 25 inches. In certain embodiments, the ceiling tile has a breadth in a range of 20 to 60 inches, for example a breadth in a range of 20 to 30 inches, such as 23 to 25 inches, or a breadth is in a range of 40 to 60 inches, such as 46 to 50 inches.

In certain embodiments as otherwise described herein, the first portion of the width of the ceiling tile is at least 5 percent of the width of the ceiling tile, e.g., at least 12 percent. In certain embodiments, the first portion is no more than 30 percent of the width of the ceiling tile, e.g., no more than 20 percent.

In certain embodiments as otherwise described herein, the body of the panel is composed of at least one of fiberglass, paper, stone wool, slag wool, perlite, metal, wood, and gypsum board. For example, in one embodiment, the body of the panel includes a combination of wood and metal. In certain embodiments, the body of the panel is composed of one of fiberglass, paper, stone wool, slag wool, perlite, metal, wood, or gypsum board. For example, ceiling tile100, shown inFIGS. 1A to 1Dhas a panel150with a body152made of gypsum board. As will be understood by those of ordinary skill in the art, the particular composition of the panel of the ceiling tile can be formed from a wide range of materials and combinations of materials

In certain embodiments as otherwise described herein, the panel includes a facing disposed on a lower side of the body. In certain embodiments, the facing comprises at least one of fiberglass, paint, veneer, or paper. For example, ceiling tile700inFIG. 7has a veneer facing755disposed on the lower surface of the body752of panel750. The use of a facing can provide a variety of different functions. For example, the facing can provide ornamentation, such as veneer facing755of tile700. In addition, the facing can provide structure to the panel, as with a paper facing on a gypsum tile. In certain embodiments as otherwise described herein, the facing extends over at least a portion of the opening of the light housing. In certain embodiments, the material of the facing has properties that disperse and/or reflect the light from the light housing, either directly as the light passes through the facing, or as reflected from the surrounding room. In other embodiments the facing provides other advantageous features as will be understood by those of ordinary skill in the art.

In certain embodiments as otherwise described herein, the planar surface extends across a majority of the panel. For example, planar surface154of tile100extends across the entirety of panel150. In other embodiments, the panel includes grooves or indents that interrupt the planar surface on the panel body. In such a case, the planar surface nonetheless extends over a majority of the panel. In still other embodiments, the planar surface covers less than a majority of the panel.

In certain embodiments as otherwise described herein, the planar surface has a texture imparted by a material of the panel body. For example, ceiling tile800inFIG. 8has a panel850with a body852formed of slag wool. As a result, the outside surfaces of the panel have a texture imparted by the slag wool. Accordingly, the planar surface854on the lower side of body852also has the texture. Nonetheless, the plane of the surface is evident from the common lower boundary of the slag wool material, as will be evident to those of ordinary skill in the art.

In certain embodiments as otherwise described herein, the panel has a thickness of at least 1/16 of an inch, e.g., ⅛ of an inch. In certain embodiments, the panel has a thickness of at least ¼ inch, e.g., at least ⅝ inch. Likewise, in certain embodiments, the panel has a thickness of no more than 3 inches, e.g., no more than 2 inches.

In certain embodiments as otherwise described herein, the light housing spans a breadth of the ceiling tile. For example, linear light housing120of ceiling tile100extends from edge112on one side of the ceiling tile to edge113at the opposite side of the ceiling tile. In other embodiments, the linear light housing extends across only a portion of the breadth of the ceiling tile. For example, in certain embodiments, the linear light housing extends across a central portion of the breadth of the ceiling tile, and is spaced apart from the side edges. In other embodiments, the light housing extends from one side across a majority of the breadth of the ceiling tile but stops short of the opposing side edge. Such a ceiling tile could be paired with another ceiling tile having a mirror image configuration so that the pair of light housings forms one elongate light. In still other embodiments, sections of light housing extend from both side edges of the ceiling tile but leave a central portion of the ceiling tile without any light housing.

In certain embodiments as otherwise described herein, the light housing includes an elongate wall and first and second end walls. For example, linear light housing120of ceiling tile100, as most clearly depicted inFIG. 10, includes elongate wall122extending from end wall124to end wall126. Elongate wall122extends across the entire breadth104of ceiling tile100where it meets end walls124and126at respective side edges112and113of the ceiling tile. Elongate wall122is curved along the width direction of ceiling tile100providing an enclosure of the housing120. As described in more detail below, the curved elongate wall forms a reflector of linear light housing120. In other embodiments, the elongate wall includes one or more planar surfaces that form an enclosure in the shape of a box.

In certain embodiments as otherwise described herein, the light housing includes an opening through which light is emitted. In some embodiments, the opening spans the breadth of the ceiling tile. For example, linear light housing120of ceiling tile100includes an opening128, as shown inFIG. 1D, through which light shines down into the area below the ceiling. The opening128of linear light housing120extends across the entire breadth of ceiling tile100from edge112to edge113. As a result, the light from ceiling tile100is presented as a long linear light across the entire ceiling tile.

In certain embodiments as otherwise described herein, the opening of the light housing is rectangular. For example, opening128is formed as a rectangle between opposing end walls124,126of the linear light housing120and between the outer edge134of the light housing and the inside edge of panel150. In other embodiments the opening is in the form of another shape. For example, in some embodiments where the ceiling tile has a shape other than a rectangle, the opening of the light housing may likewise not be rectangular. For example, in some embodiments of a ceiling tile with a triangular shape, the opening of the light housing is in the shape of a trapezoid. In other embodiments the opening is round, as in ceiling tile200. In certain embodiments the opening is in the shape of an arc, as in ceiling tile300.

In certain embodiments as otherwise described herein, the opening of the light housing has a width of at least 1 inch, e.g., at least 2 inches, e.g., at least 3 inches. In certain embodiments, the opening of the light housing has a width of no more than 12 inches, e.g., no more than 8 inches. Of course, a person of ordinary skill in the art will appreciate that the opening of the light housing can have other sizes as appropriate based on the size of the tile and the area to be illuminated.

In certain embodiments as otherwise described herein, the ceiling tile includes a light source that cooperates with the light housing. In certain embodiments the light source is disposed in the light housing. Further, in certain embodiments the light source is disposed on an upper side of the panel. For example, in ceiling tile100, light source170is positioned within linear light housing120on the inside edge of the housing. As most easily seen in the cross section ofFIGS. 1A and 1D, light source170is held on a portion of linear light housing120that extends over a narrow part of panel150. As will be appreciated by those of ordinary skill in the art, the light source may be coupled to the light housing using a variety of different methods and structures, such as adhesives, fasteners and/or brackets.

In other embodiments, the light source is remote from the light housing and shines light into the light housing from a distance. For example, in some embodiments the light source is disposed at a far edge of the ceiling tile and shines light into the light housing through an opening therein. In such an embodiment, the light housing serves to redirect the light downward toward the room or space that is covered by the constructed ceiling. In other embodiments, the ceiling tile does not itself include a light source. Instead, light is directed to the light housing from a remote location either directly, or through fiber optics, or by another method as will appreciated by a person of ordinary skill in the art.

In various embodiments, the light source itself is not substantially directly visible from a point under the bottom of the ceiling tile; the light source can instead be configured to shine up onto a reflector, which directs light down to points under the bottom of the ceiling tile. Such configurations are shown throughout the drawings.

In certain embodiments as otherwise described herein, the light source of the ceiling tile includes an array of LEDs. The array of LEDs includes one or more columns of LEDs that provide light along the length of the lighting housing. Because LEDs are small, the array can extend up to the very edge of the lighting housing with individual LEDs located close to the end walls of the housing. In certain embodiments the LEDs in neighboring columns are aligned, while in other embodiments the LEDs in neighboring columns are offset. In certain embodiments, the array includes a single column of LEDs. For example, in ceiling tile100, the light source170is formed by an array of LEDs having only one column. In particular, the LED array in ceiling tile100is an LED strip with a plurality of LEDs on a flexible circuit board. In other embodiments, the LEDs are disposed on one or more rigid backing, such as printed circuit boards.

In certain embodiments as otherwise described herein that have a light source with at least one LED, the ceiling tile includes an LED driver disposed on an upper surface of the panel. For example, ceiling tile100includes LED driver172disposed on the upper surface156of panel150. The LED driver172regulates the power to the LEDs of light source170in order to provide changing power to the LEDs as their electrical properties change with temperature. Accordingly, the LED driver allows the LEDs to emit a steady stream of light over the course of their operation. As will be appreciated by those of ordinary skill in the art the LED driver can be electrically connected to the LEDs of the LED array in a variety of different manners. For example, the LED driver can be connected by electrical leads to the circuit board or other backing of the LED array, which in turn provides power to the LEDs. As will be appreciated by those of ordinary skill in the art, the LED driver may be attached to the panel using a variety of different methods and structures, such as adhesives, fasteners and/or brackets. In certain embodiments as otherwise described herein, the LED driver is disposed on the light housing. For example, in some embodiments, the light housing includes a platform or other surface on which the LED driver is attached.

In certain embodiments as otherwise described herein, the ceiling tile includes an electronic controller including a memory for storing instructions and a processor to carry out the instructions. For example, in some embodiments the electronic controller includes instructions for operating the light source according to one or more varying lighting schemes as will be appreciated by a person of ordinary skill in the art, such as changing color or varying brightness at different times of the day. In certain embodiments the electronic controller includes one or more sensors that collects data that is stored in the memory and/or used by the processor. For example, in some embodiments the electronic controller includes a light sensor and the processor sends control signals for controlling the light source based on the light sensor. In certain embodiments the electronic controller includes a data transceiver for sending and/or receiving data. For example, in some embodiments the electronic controller includes a wireless data transceiver. As will be appreciated by a person of ordinary skill in the art, the data transceiver can be used to send data collected by the sensors and/or to receive updated instructions for operating the controller. In certain embodiments, the electronic controller is associated with the LED driver, for example, in some embodiments the LED driver is a module of the electronic controller.

In certain embodiments as otherwise described herein, the light source includes one or more fluorescent, halogen or incandescent bulbs. For example, in some embodiments, the light source includes a plurality of small incandescent or halogen bulbs arranged in a line similar to the LEDs of light source170in ceiling tile100. In other embodiments, the light source includes one or two long bulbs that extend along the length of the linear light housing.

In certain embodiments as otherwise described herein that have a light source with at least one fluorescent bulb, the ceiling tile further includes a fluorescent light ballast disposed on an upper surface of the panel. The fluorescent light ballast regulates current to the fluorescent bulb by adding impedance to the circuit of the fluorescent bulb as the voltage drop across the bulb changes. As will be appreciated by those of ordinary skill in the art, the fluorescent light ballast can be electrically connected to the fluorescent bulb in a variety of different manners. For example, the ballast can be connected by electrical leads to a socket that receives the fluorescent bulb. As also will be appreciated by those of ordinary skill in the art, the fluorescent light ballast may be attached to the panel using a variety of different methods and structures, such as adhesives, fasteners and/or brackets.

In certain embodiments as otherwise described herein, the fluorescent light ballast is disposed on the light housing. For example, in some embodiments, the light housing includes a platform or other surface on which the fluorescent ballast is attached. Further, in other embodiments the fluorescent light ballast is integrated with the fluorescent bulb, and a separate ballast is omitted.

In certain embodiments as otherwise described herein, the light source is configured to emit light through the opening that is substantially uniform along the length of the opening. The term substantially uniform as used herein means a difference in lux of no more than 20% between any two respective square inches of space along the length of the opening of the light housing. In such an embodiment, although the light emission along the length of light housing is substantially uniform, more substantial differences in light emission may be noticed across the width of the opening. The substantially uniform light emission along the length of the light housing can be achieved in a variety of manners. For example, in ceiling tile100, the column of LEDs of light source170extend up to the end walls124,126of the linear light housing120, such that light of similar intensity is emitted along the entire length of the linear light housing120. In certain embodiments, the light source includes an electrical connector and the electrical connector is disposed on a long side of the light source. For example in ceiling tile900shown inFIG. 9, the light source includes a linestra bulb with an electrical connector974including two sockets that are disposed at either end of the bulb on the side of the bulb. This allows the bulb itself to extend up to the end walls924,926of light housing920. In certain embodiments, the light source includes an electrical connector and the electrical connector is not disposed at an end of the light housing. For example, in ceiling tile1000shown inFIG. 10, the light source1070includes two twin tube compact fluorescent bulbs that extend outward from a center of the light housing1020. The electrical connector1074includes two sockets disposed at the center of the light housing. This allows the distal ends of the bulbs, which emit light, to be positioned near the end walls1024,1026of the linear light housing1020and provide uniform light across the entire housing.

In certain embodiments, the ceiling tile further includes a light reflector disposed in the light housing. For example, the elongate wall122of linear light housing120of ceiling tile100serves as the light reflector180. Reflector180redirects the light that is shining at an upward angle from the LEDs of light source170downward through an opening128into the room that is covered by the ceiling tile.

While the reflector180forms the elongate wall122of linear light housing120in the embodiment of ceiling tile100, in other embodiments the reflector is separate from the wall of the housing and disposed inside the light housing. For example, in certain embodiments the light reflector includes a film, coating, or glass layer disposed over the wall of the light housing. In other embodiments, the reflector is spaced from the wall of the housing. For example, in some embodiments the reflector is a glass or metal sheet separate from the housing wall and disposed in the lighting housing. In certain embodiments the reflector and the panel are formed of the same material, e.g., metal or gypsum.

In certain embodiments as otherwise described herein, the light reflector is formed of metal, e.g., steel or aluminum. In other embodiments, the light reflector is formed of plastic, e.g., acrylic, polycarbonate, an acrylonitrile/butadiene/styrene polymer (ABS) or polyethylene terephthalate (PET). The reflector need not have a mirrored surface; in many embodiments the reflector will act to diffuse the light that it reflects. Still in other embodiments the light reflector is formed of glass.

In certain embodiments as otherwise described herein, the light housing includes an opening, and the light reflector faces the opening. In certain embodiments, the light reflector is curved and concave. For example, light reflector180of ceiling tile100is positioned over opening128and has a concave curve that directs a large portion of the light emitted from light source170through opening128. As will be appreciated by those of ordinary skill in the art, the angle of the light source and the curve of the reflector can be tailored so that the reflector redirects light that is spreading from the light source over a range of angles.

In certain embodiments as otherwise described herein, the light reflector is at an angle to the plane of the ceiling. For example, in some embodiments the light reflector is flat and is positioned at an appropriate angle to direct light from the light source through the opening of the light housing and into the room.

In certain embodiments as otherwise described herein, the light reflector is a diffuse reflector. The diffuse reflector scatters light from the light source to reflect the light over a range of angles. In certain embodiments the light source is non-diffuse. For example, in some embodiments the light source is formed by one or more incandescent bulbs that emit light from a filament. The filament provides the light from a point or a very small area. The diffuse reflector softens the light by spreading it over a larger area before it is directed into the room below the ceiling tile. In certain embodiments the reflector has a multi-faceted surface to spread the light, while in other embodiments the reflector has a smooth surface.

In certain embodiments as otherwise described herein, the light reflector includes a diffuse paint. In some embodiments the light reflector includes a roughened metal surface. In other embodiments the light reflector is formed of a white plastic, e.g., white PET or ABS.

In certain embodiments the light reflector is not a diffuse reflector. For example, in certain embodiments the light reflector has a mirror-like surface. In some of these embodiments the light source is configured to shine diffuse light onto the light reflector. Accordingly, while most of the reflection of the mirror-like surface of the reflector is specular, the diffuse light source provides light that is spread over a larger area to avoid the appearance of a point light source. For example, in certain embodiments as otherwise described herein, the light source includes a diffuser that spreads the light evenly over the light reflector.

Another aspect of the present disclosure is a ceiling system including a ceiling grid having a plurality of beams that define a plane of the ceiling, a plurality of first ceiling tiles supported by the ceiling grid, and one or more second ceiling tiles with an integrated light in accordance with any of the embodiments described above. Such a system is shown inFIGS. 11 to 13, which shows a portion of the system in the corner of a room adjacent to two perpendicular adjoining walls. Ceiling system1190includes a ceiling grid1140(most clearly shown in the schematic top view ofFIG. 11) that includes a plurality of beams1142extending in perpendicular directions from the supporting walls. The beams1142include T-beams1143that span the room and channels1144that are adjacent to the supporting walls. The beams1142are arranged in a perpendicular grid and provide openings that hold respective ceiling tiles. Ceiling system1190includes two groups of ceiling tiles: a group of first ceiling tiles1192that are conventional flat ceiling tiles, and a group of second ceiling tiles1100that each include an integrated linear light similar to ceiling tile100discussed above. The ceiling tiles are schematically depicted in the top view ofFIG. 12and the bottom perspective view ofFIG. 13.

In certain embodiments as otherwise described herein, each first ceiling tile includes a panel that is coplanar with the panel of the second ceiling tiles. Further, in certain embodiments, the panel of each first ceiling tile includes a planar surface, and wherein the planar surface of each first ceiling tile is coplanar with the planar surface of the second ceiling tile. For example, first ceiling tiles1192include panels1195that are coplanar with the panels1150of second ceiling tiles1100, and specifically include planar surfaces1196that are coplanar with the planar surfaces1154of second tiles1100. As a result, the panels1195,1150of the ceiling tiles form a continuous planar ceiling surface that extends across the majority of the room, except where the linear lighting is provided by second ceiling tiles1100.

In certain embodiments as otherwise described herein, the panel of each first ceiling tile extends across an entire width of the respective ceiling tile. For example, in contrast to the panels1150of second ceiling tiles1100, which extend across only a portion of the respective tile's width, the panels1195of first tiles1192span the entire width of the tile.

In certain embodiments as otherwise described herein, each first ceiling tile is rectangular and has a width and a breadth, and each second ceiling tile is rectangular and has a width and a breadth that is the same as the width and the breadth of the first ceiling tiles. For example, the first ceiling tiles1192and second ceiling tiles1100are all squares of the same size, and thus have the same respective breadth and width. Accordingly, the first and second ceiling tiles1192,1100can easily be moved to different openings in the ceiling grid, allowing simple modification of the ceiling system1190.

In certain embodiments as otherwise described herein, the second ceiling tile is removable from the ceiling grid by lifting the second ceiling tile. For example, second ceiling tile1100can be removed from the ceiling grid1140by simply lifting the tile up and out of the opening in the grid. The complete decoupling of the second ceiling tile1100from the ceiling system1190requires disconnecting electrical connections to the ceiling tile. However, removing tile1100does not require removal of any metal fasteners or any portion of the grid.

In certain embodiments as otherwise described herein, the second ceiling tile includes a contact surface disposed around a perimeter thereof, and the contact surface is supported by the beams of the ceiling grid. In certain embodiments, the beams of the ceiling grid include T-beams, and the contact surface of the second ceiling tile rests on flanges of a portion of the beams of the ceiling grid. For example, grid1140of ceiling system1190includes rows and columns of T-beams1143that form openings to hold the ceiling tiles. In particular, the flanges of the T-beams (seeFIG. 11) form a square surface that supports the contact surface around the perimeter of the ceiling tiles. (A cross section of the flanges of opposing T-beams supporting a ceiling tile is shown inFIG. 1.)

In certain embodiments as otherwise described herein, each tile in the group of second ceiling tiles is disposed adjacent to at least one other tile in the group of second ceiling tiles. In certain embodiments, the tiles in the group of second ceiling tiles are disposed in a line within the ceiling grid. For example, in ceiling system1190, three second ceiling tiles1100form a group that is disposed in a straight line within the ceiling grid1140. In other embodiments, the second ceiling tiles are organized in a cluster, for example with the linear light housings forming a pinwheel configuration. In certain embodiments, the tiles in the group of second ceiling tiles are disposed in a meandering path. For example, in ceiling system1490, the second ceiling tiles1400are each disposed adjacent to another second ceiling tile1400to form a path of ceiling tiles. In other embodiments, the tiles in the group of second ceiling tiles are disposed in a loop. For example, in ceiling system1590, the second ceiling tiles1500are arranged in a loop of eight tiles. While the loop in ceiling system1590surrounds a conventional ceiling tile1592, in other embodiments the loop of second ceiling tiles is compact and does not surround any other tiles.

In certain embodiments as otherwise described herein, the tiles in the group of second ceiling tiles have the same orientation, such that the respective light housings form a continuing linear light across the group of second ceiling tiles. For example, second ceiling tiles1100in ceiling system1190are arranged in a line where each tile is rotated in the same direction. As a result, the linear light housings combine to form one continuous linear light crossing a portion of the room.

In certain embodiments as otherwise described herein, the tiles in the group of second ceiling tiles are oriented to form a continuing path of light among the group of second ceiling tiles. For example, in ceiling system1490, the tiles are arranged adjacent to one another in a path and the light housings of the tiles are oriented to form a continuing path of light in a staircase pattern across the group of second ceiling tiles1400.

In certain embodiments as otherwise described herein, the tiles in the group of second ceiling tiles are oriented to form a continuous loop of light among the second ceiling tiles. For example, in ceiling system1590, the second ceiling tiles1500are arranged in a loop and are oriented so that the light housings also form a loop. Accordingly, when illuminated, the group of second ceiling tiles1500forms a continuous loop of light in the ceiling.

Another aspect of the present disclosure is a method of installing ceiling tiles in a ceiling that includes: providing a ceiling grid including a plurality of beams defining a plane and arranged to provide a plurality of openings for ceiling tiles; placing a plurality of first ceiling tiles in a first portion of the openings; and placing one or more second ceiling tiles in at least one other opening in the ceiling grid so as to form a ceiling system according to any of the embodiments described above.

Another aspect of the present disclosure is a method of installing ceiling tiles in a ceiling, the method comprising: providing a ceiling grid including a plurality of beams defining a plane and arranged to provide a plurality of openings for ceiling tiles; placing a first ceiling tile in a first opening in the ceiling grid; placing a second ceiling tile in a second opening in the ceiling grid, where the second ceiling tile is one including an integrated light as described in any of the embodiments above.

In certain embodiments as otherwise described herein, the method includes placing an additional second ceiling tile in a third opening adjacent to the second opening. In certain embodiments, the method includes positioning the second ceiling tiles to form a continuing linear light using the respective linear light housings. For example, second ceiling tiles1100in ceiling system1190were each rotated in the same manner before being placed within respective openings in the ceiling grid. Accordingly, the second ceiling tiles1100form a linear light across all three tiles.

In certain embodiments as otherwise described herein, the method includes placing a group of second ceiling tiles in respective adjacent openings in the ceiling grid. In certain embodiments, the method includes orienting the group of second ceiling tiles to form a continuing path of light among the second ceiling tiles. For example, as the tiles in ceiling system1490are placed into the ceiling grid, the second ceiling tiles1400are oriented form a continuing path of light in a staircase pattern across the group of second ceiling tiles1400. In other embodiments, the method includes orienting the group of second ceiling tiles to form a continuous loop of light among the second ceiling tiles. For example, as the tiles in ceiling system1590are placed into ceiling grid the second ceiling tiles1500are oriented to form a continuous loop of light around ceiling tile1592.

In certain embodiments as otherwise described herein, placing the second ceiling tile in the second opening includes lowering the second ceiling tile onto a group of the plurality of beams. For example, the second ceiling tile with the integrated light can be installed in the ceiling through the simple act of dropping the tile into the appropriate opening. Thus, attractive lighting, e.g., linear lighting, can be constructed without the need for building customized ceiling grid to accommodate the lighting, or for attaching linear lighting fixtures to the grid using metal fasteners. Instead, the light can be constructed as simply as installing ceiling tiles and providing an electrical connection to any corresponding light source.

Various aspects of the disclosure are further described by the following enumerated embodiments, which can be combined in any number and in any fashion that is not technically or logically inconsistent.

A ceiling tile comprising:a light housing extending across a first portion of a width of the ceiling tile; anda panel extending across a remaining portion of the width of the ceiling tile.

The ceiling tile according to Embodiment 1, wherein the light housing is a linear light housing.

The ceiling tile according to Embodiment 1 or Embodiment 2, wherein the light housing extends from a first edge of the ceiling tile.

The ceiling tile according to Embodiment 1, wherein the light housing is nonlinear.

The ceiling tile according to any of Embodiments 1 to 4, wherein the panel includes a body having a planar surface.

The ceiling tile according to Embodiment 5, wherein the planar surface is parallel to a plane of the ceiling.

The ceiling tile according to any of Embodiments 1 to 6, further comprising a contact surface disposed around a perimeter of the ceiling tile, the contact surface defining the plane of the ceiling.

The ceiling tile according to Embodiment 7, wherein the contact surface includes an outer edge of the light housing.

The ceiling tile according to Embodiment 7 or Embodiment 8, wherein the panel includes a planar surface and wherein the contact surface includes a portion of the planar surface of the panel.

The ceiling tile according to any of Embodiments 7 to 9, wherein the contact surface includes a lower surface of a projection extending from an outer edge of the panel.

The ceiling tile according to any of Embodiments 7 to 10, further comprising at least one clip attached to the panel, and wherein the contact surface includes a surface of the at least one clip.

The ceiling tile according to any of Embodiments 1 to 11, wherein the ceiling tile is rectangular.

The ceiling tile according to any of Embodiments 1 to 12, wherein the width is in a range of 20 to 30 inches, e.g., 23 to 25 inches.

The ceiling tile according to any of Embodiments 1 to 13, wherein the ceiling tile has a breadth in a range of 20 to 60 inches.

The ceiling tile according to any of Embodiments 1 to 14, wherein the breadth is in a range of 20 to 30 inches, e.g., 23 to 25 inches.

The ceiling tile according to any of Embodiments 1 to 15, wherein the breadth is in a range of 40 to 60 inches, e.g., 46 to 50 inches.

The ceiling tile according to any of Embodiments 1 to 16, wherein the first portion is at least 5 percent of the width of the ceiling tile, e.g., at least 12 percent.

The ceiling tile according to any of Embodiments 1 to 17, wherein the first portion is no more than 30 percent of the width of the ceiling tile, e.g., no more than 20 percent.

The ceiling tile according to any of Embodiments 1 to 18, wherein the panel includes a body composed of at least one of fiberglass, paper, stone wool, slag wool, perlite, metal, wood, and gypsum board.

The ceiling tile according to any of Embodiments 1 to 19, wherein the panel includes a body composed of one of fiberglass, paper, stone wool, slag wool, perlite, metal, wood, or gypsum board.

The ceiling tile according to any of Embodiments 1 to 20, wherein the panel includes a facing material disposed on a lower side of the body.

The ceiling tile according to Embodiment 21, wherein the facing material comprises at least one of fiberglass, paint, veneer or paper.

The ceiling tile according to any of Embodiments 1 to 22, wherein the panel includes a planar surface that extends across a majority of the panel.

The ceiling tile according to any of Embodiments 1 to 23, wherein the panel includes a planar surface that has a texture imparted by a material of the panel body.

The ceiling tile according to any of Embodiments 1 to 24, wherein the panel has a thickness of at least 1/16 inch, e.g., at least ⅛ inch, e.g., at least ¼ inch, e.g., at least ⅝ inch.

The ceiling tile according to any of Embodiments 1 to 25, wherein the panel has a thickness of no more than 3 inches, e.g., no more than 2 inches.

The ceiling tile according to any of Embodiments 1 to 26, wherein the light housing spans a breadth of the ceiling tile.

The ceiling tile according to any of Embodiments 1 to 27, wherein the light housing includes an elongate wall and first and second end walls.

The ceiling tile according to any of Embodiments 1 to 28, wherein the light housing includes an opening through which light is emitted.

The ceiling tile according to Embodiment 29, wherein the opening spans a breadth of the ceiling tile.

The ceiling tile according to Embodiment 29 or Embodiment 30, wherein the opening is rectangular.

The ceiling tile according to any of Embodiments 29 to 31, wherein the opening has a width of at least 1 inch, e.g., at least 2 inches, e.g., at least 3 inches.

The ceiling tile according to any of Embodiments 29 to 32, wherein the opening has a width of no more than 12 inches, e.g., no more than 8 inches.

The ceiling tile according to any of Embodiments 1 to 33, further comprising a light source that cooperates with the light housing.

The ceiling tile according to Embodiment 34, wherein the light source is disposed in the light housing.

The ceiling tile according to Embodiment 34 or Embodiment 35, wherein the light source is disposed on an upper side of the panel.

The ceiling tile according to any of Embodiments 34 to 36, wherein the light source comprises an array of LEDs.

The ceiling tile according to Embodiment 37, wherein the array includes a single column of LEDs.

The ceiling tile according to Embodiment 37 or Embodiment 38, further comprising an LED driver disposed on an upper surface of the panel.

The ceiling tile according to Embodiment 37 or Embodiment 38, further comprising an LED driver disposed on the light housing.

The ceiling tile according to any of Embodiments 34 to 36, wherein the lights source comprises at least one halogen or incandescent bulb.

The ceiling tile according to any of Embodiments 34 to 36, wherein the light source comprises a fluorescent bulb.

The ceiling tile according to Embodiment 42, further comprising a fluorescent light ballast disposed on an upper surface of the panel.

The ceiling tile according to Embodiment 42, further comprising a fluorescent light ballast disposed on the light housing.

The ceiling tile according to any of Embodiments 34 to 44, wherein the light housing includes an opening, and wherein the light source is configured to emit light through the opening that is substantially uniform along the length of the opening.

The ceiling tile according to any of Embodiments 34 to 45, wherein the light source includes an electrical connector and the electrical connector is disposed on a long side of the light source.

The ceiling tile according to any of Embodiments 34 to 46, wherein the light source includes an electrical connector, and wherein the electrical connector is not disposed at an end of the light source.

The ceiling tile according to any of Embodiments 1 to 47, further comprising a light reflector disposed in the light housing.

The ceiling tile according to Embodiment 48, wherein the light reflector is formed of metal, e.g., steel or aluminum.

The ceiling tile according to Embodiment 48, wherein the light reflector is formed of plastic, e.g., acrylic, polycarbonate, ABS or PET.

The ceiling tile according to any of Embodiments 48 to 50, wherein the light housing includes an opening, and wherein the light reflector faces the opening.

The ceiling tile according to any of Embodiments 48 to 51, wherein the light reflector is curved and concave.

The ceiling tile according to any of Embodiments 48 to 51, wherein the light reflector is at an angle to the plane of the ceiling.

The ceiling tile according to any of Embodiments 48 to 53, wherein the light housing includes an elongate wall, and wherein the light reflector is formed on a surface of the elongate wall.

The ceiling tile according to any of Embodiments 48 to 54, wherein the light reflector is a diffuse reflector.

The ceiling tile according to Embodiment 55, wherein the light source is non-diffuse.

The ceiling tile according to Embodiment 55 or Embodiment 56, wherein the light reflector includes a diffuse paint.

The ceiling tile according to Embodiment 55 or Embodiment 56, wherein the light reflector includes a roughened metal surface.

The ceiling tile according to Embodiment 55 or Embodiment 56, wherein the light reflector is formed of a white plastic, e.g., white PET or ABS.

The ceiling tile according to any of Embodiments 48 to 54, wherein the light reflector has a mirror-like surface.

The ceiling tile according to Embodiment 60, wherein the light source includes a diffuser.

The ceiling tile according to any of Embodiments 48 to 61, wherein the light source further comprises a light source that cooperates with the light housing and is not directly visible from a point under the bottom of the ceiling tile, and wherein the light source is configured to shine up onto the light reflector, which directs light to points under the bottom of the ceiling tile.

A ceiling system comprising:a ceiling grid including a plurality of beams defining a plane of the ceiling;a plurality of first ceiling tiles supported by the ceiling grid; andone or more second ceiling tiles according to any of Embodiments 1 to 62 supported by the ceiling grid.

The ceiling system according to Embodiment 63, wherein each first ceiling tile includes a panel that is coplanar with the panel of the second ceiling tile.

The ceiling system according to Embodiment 64, wherein the panel of each first ceiling tile includes a planar surface, and wherein the planar surface of each first ceiling tile is coplanar with the planar surface of the second ceiling tile.

The ceiling system according to Embodiment 64 or Embodiment 65, wherein the panel of each first ceiling tile extends across an entire breadth of the respective ceiling tile.

The ceiling system according to any of Embodiments 63 to 66, wherein each first ceiling tile is rectangular and has a width and a breadth, and wherein the second ceiling tile is rectangular and has a width and a breadth that is the same as the width and the breadth of the first ceiling tiles.

The ceiling system according to any of Embodiments 63 to 67, wherein the second ceiling tile is removable from the ceiling grid by lifting the second ceiling tile.

The ceiling system according to any of Embodiments 63 to 68, wherein the second ceiling tile includes a contact surface disposed around a perimeter thereof, and wherein the contact surface is supported by the beams of the ceiling grid.

The ceiling system according to Embodiment 69, wherein the beams of the ceiling grid include T-beams, and

wherein the contact surface of the second ceiling tile rests on flanges of a portion of the beams of the ceiling grid.

The ceiling system according to any of Embodiments 63 to 70, wherein the one or more second ceiling tiles includes a group of second ceiling tiles.

The ceiling system according to Embodiment 71, wherein each tile in the group of second ceiling tiles is disposed adjacent to at least one other tile in the group of second ceiling tiles.

The ceiling system according to Embodiment 72, wherein the tiles in the group of second ceiling tiles are disposed in a line within the ceiling grid.

The ceiling system according to Embodiment 73, wherein the tiles in the group of second ceiling tiles have the same orientation, such that the respective light housings form a continuing linear light across the group of second ceiling tiles.

The ceiling system according to Embodiment 72, wherein the tiles in the group of second ceiling tiles are oriented to form a continuing path of light across the group of second ceiling tiles.

The ceiling system according to Embodiment 72, wherein the tiles in the group of second ceiling tiles are oriented to form a continuous loop of light.

A method of installing ceiling tiles in a ceiling, the method comprising:providing a ceiling grid including a plurality of beams defining a plane and arranged to provide a plurality of openings for ceiling tiles;placing a plurality of first ceiling tiles in a first portion of the openings; andplacing one or more second ceiling tiles in at least one other opening in the ceiling grid so as to form a ceiling system according to any of Embodiments 63 to 76.

A method of installing ceiling tiles in a ceiling, the method comprising:providing a ceiling grid including a plurality of beams defining a plane and arranged to provide a plurality of openings for ceiling tiles;placing a first ceiling tile in a first opening in the ceiling grid;placing a second ceiling tile according to any of Embodiments 1 to 62 in a second opening in the ceiling grid.

The method according to Embodiment 78, further comprising placing an additional second ceiling tile in a third opening adjacent to the second opening.

The method according to Embodiment 79, further comprising positioning the second ceiling tiles to form a continuing linear light using the respective light housings.

The method according to Embodiment 78 or Embodiment 79, further comprising placing a group of second ceiling tiles in respective adjacent openings in the ceiling grid.

The method according to Embodiment 81, further comprising orienting the group of second ceiling tiles to form a continuing path of light among the second ceiling tiles.

The method according to Embodiment 81, further comprising orienting the group of second ceiling tiles to form a continuous loop of light among the second ceiling tiles.

The method according to any of Embodiments 78 to 83, wherein the placing the second ceiling tile in the second opening includes lowering the second ceiling tile onto a group of the plurality of beams.

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.