Patent Publication Number: US-2013239493-A1

Title: Suspended ceiling panel system for residential and commercial buildings

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/610,516, filed on Mar. 14, 2012. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates generally to a suspended ceiling panel system for residential and commercial buildings. More particularly, the invention relates to a suspended ceiling panel system that includes a panel formed from a grid molding and a trim molding that is in turn mounted on T-shaped frame members that are joined to create a grid. The ceiling panels are designed to accommodate various ceiling structures such as sprinkler heads, exit signs, heating ventilation and air conditioning ductwork and lights. The suspended ceiling panel system is easy to assemble and results in a uniform appearance that is aesthetically pleasing to the eye. Moreover, the suspended ceiling panel system of the present invention is easy to install and provides increased insulation characteristics over prior art suspended ceiling panel system, and also provides increased noise reduction and/or reduces sound transmission through the ceiling panel, while still providing fire resistance, bacteria resistance and moisture resistance. 
     2. Background Art 
     Many types of buildings, such as commercial and government office buildings, utilize suspended ceilings. Suspended ceilings typically include a suspension grid system and acoustical panels. The grid system, for example, may be used to suspend the panels from the overhead building structure generally in a single plane. The suspended ceiling is formed by attaching the grid to hanger wires that are in turn attached to the building structure, and thus the load of the grid system with its associated lighting components, airflow distribution components, and acoustical panels is transferred to the building structure by the hanger wires. A variety of types of lay-in ceiling panels are available for use with exposed grids including cast, water felted, fiberglass, gypsum, and metal. 
     Grid systems may be formed using inverted T-shaped main beams, inverted T-shaped crossbeams, and hangars. The main beams are metal framing members that are hung from the hangars. The cross beams typically are metal framing members snap fitted to the main beams, perpendicular thereto. 
     One popular variant of the suspended ceiling is a prior art suspended ceiling system that utilizes a grid frame that includes inverted T-shaped frame members for the main beams and cross beams. The frame members are configured in such a manner to form a suspended grid that includes multiple grid elements, which are known as modules. These modules may be provided in any practicable size, with about 24 in. squares and about 24 in.×48 in. rectangles being a common module size. The suspended ceiling is formed by installing ceiling panels into the modules such that each edge portion of the bottom surface of each panel is supported by an inverted T-bar main beam or cross beam. The prior art suspended ceiling panel system is completed by incorporating required utilities into the system such as sprinkler heads, heating, ventilation and air conditioning (HVAC) elements, and lighting fixtures. Suspended ceiling panel systems, for example, may provide decoration, light reflection, and/or masking of utility infrastructure. 
     A prior art system for suspending ceiling panels have been popular for both commercial and residential buildings. These prior art systems allow the installation of a ceiling panel, which is typically minimally acoustically absorbent and is aesthetically pleasing. These prior art ceiling systems, moreover, can be relatively quickly and easily installed. Prior art suspended ceiling panel systems are particularly desired for hiding pipes, wiring, and air duct systems that are common in many buildings. 
     In many applications, it is desirable that a suspended ceiling panel system provide significant degree of acoustic insulation or damping. In particular, in an office environment where speech privacy is important, it is desirable to limit the amount of sound that can otherwise travel through the ceiling from one office to an adjacent office, or from one room to an adjacent room. 
     Utilizing ceiling panels made from sound absorbing materials can provide a measure of acoustic insulation in a suspended ceiling system. For example, U.S. Pat. No. 5,832,685 to Hermanson is directed to a self-supporting, sound absorbing, interior surface panel as well as a suspended ceiling module comprising a support structure, such as a T-bar grid, and a panel, which could be supported within the module in either tegular or coffered orientation. 
     Using sound absorbing ceiling tiles alone, however, does not provide acoustic insulation of modules of a suspended ceiling system where lighting fixtures or other utilities, such as signs, airflow ducts or sprinkler heads are installed. To this end, various additional devices have been introduced to providing acoustic insulation with respect to those fixtures. 
     In addition, prior art suspended ceiling systems utilize insulation components that typically are not resistant to bacteria and/or moisture and therefore, can provide an environment for bacterial infestation and propagation that can lead to discoloration or transmission of the bacterial component into the room. When the prior art suspended ceiling panel systems are utilized in an environment that needs to be maintained sterile, such as a hospital operating room or an outpatient surgical operating room, the existence of such a bacterial component can be especially problematic. 
     In view of these developments, there remains a need for an improved suspended ceiling panel system that can be utilized in connection with standard inverted T-shaped main beams and cross beams, and which provides accommodation for various ceiling structures such as sprinkler heads, exit signs, heating ventilation and air conditioning ductwork and lights. Moreover, there also remains a need for an improved suspended ceiling panel system that is easy to assemble and has a uniform appearance that is aesthetically pleasing to the eye. Furthermore, there also remains a need for an improved suspended ceiling panel system that provides better insulation characteristics over the prior art suspended ceiling panel systems, and also provides better noise reduction and/or reduced sound transmission through the ceiling panel while still providing fire resistance, bacterial resistance and moisture resistance. 
     SUMMARY OF THE INVENTION 
     Objectives of the present invention include providing a suspended ceiling panel system for residential and commercial buildings that accommodates various ceiling structures such as sprinkler heads, exit signs, heating ventilation and air conditioning ductwork, lights, and the like. 
     A further objective of the present invention is to provide a suspended ceiling panel system for residential and commercial buildings that is easy to assemble, has a uniform appearance that is aesthetically pleasing to the eye, and that obscures the main beams and cross beams of the grid system. 
     Yet another objective of the present invention is to provide a suspended ceiling panel system for residential and commercial buildings that demonstrates improved insulation characteristics. 
     Still another objective of the present invention is to provide a suspended ceiling panel system for residential and commercial buildings having improved noise reduction properties resulting in reduced sound transmission through the ceiling panel and still provides fire resistance, bacterial resistance and moisture resistance. 
     These objectives and advantages are obtained by the suspended ceiling panel system, comprising: a grid system which includes a main beam and a cross beam; a panel which includes a grid molding and a trim molding; the grid molding disposed upon at least one of the main beam and the cross beam of the grid system; and the trim molding attached to the grid molding such that a portion of the main beam or the cross beam is disposed between the trim molding and the grid molding. 
     These objectives and advantages are also obtained by the method of assembly of a suspended ceiling panel system for residential and commercial buildings, said method comprising the steps of: providing a grid system which includes a main beam and a cross beam; providing a panel which includes a grid molding and a trim molding; disposing the grid molding on at least one of the main beam and the cross beam of the grid system; and attaching the trim molding to the grid molding such that a portion of the main beam or the cross beam is disposed between the trim molding and the grid molding. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The preferred embodiment of the present invention, illustrative of the best mode in which applicants have contemplated applying the principles, is set forth in the following description and is shown in the drawings, and is particularly and distinctly pointed out and set forth in the appended claims. 
         FIG. 1  is a fragmentary bottom perspective view of a prior art suspended ceiling panel system, showing the frame members consisting of main beams and cross beams forming the grid and showing the panels of the ceiling panel system disposed onto the upper surfaces of the frame members; 
         FIG. 2  is a top perspective view of a ceiling panel of the ceiling panel system of the present invention, showing the grid moldings extending along the four sides of the panel and showing the trim molding attached to the bottom portion of the grid molding of the of the panel; 
         FIG. 2A  is a bottom perspective view similar to the view shown in  FIG. 1 , showing the trim molding attached to the bottom portion of the grid molding with the cloth covering of the trim molding removed and showing the stone wool insulation seated within the grid molding; 
         FIG. 3  is an interior perspective view of a single side of the grid molding and trim molding with the stone wool insulation and other components of the ceiling panel removed, showing the attachment means of the trim molding to the grid molding of the ceiling panel system; 
         FIG. 4  is a cross sectional view of the trim molding and the grid molding prior to installation of the trim molding onto the grid molding, showing the lower leg of the grid molding extending downwardly toward the interior vertical member of the trim molding; 
         FIG. 5  is a fragmentary cross sectional view of adjacent grid moldings of adjacent ceiling panels mounted on an inverted T-shaped main beam of an existing grid system, showing the grid molding seated on the main beam and including stone wool insulation, an LED light, and showing the trim molding attached to the lower leg portion of the grid molding, and also showing the cloth formed over the trim molding; 
         FIG. 6  is a top exploded perspective view of alternate configurations of the ceiling panels that can be incorporated into the ceiling panel system of the present invention, showing panel configurations for lighting, exit signs, sprinkler heads, and duct work that are easily incorporated into the ceiling panel system of the present invention; 
         FIG. 7  is a bottom exploded view of the alternate configurations of the ceiling panels of the ceiling panel system of the present invention shown in  FIG. 6 ; and 
         FIG. 8  is a fragmentary cross sectional view of a ceiling panel of the ceiling panel system of the present invention, showing the grid molding that surrounds the insulation and an LED light bar seated on the inverted T-shaped main beam and including the trim molding attached to the grid molding, and showing the trim molding covered by cloth. 
     
    
    
     Similar numerals referred to similar parts throughout the drawings. 
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In order to better understand the structure, assembly, and operation of the preferred embodiment suspended ceiling panel system of the present invention, the structure and installation of a prior art suspended ceiling panel system will be described in detail below. 
     Turning now to  FIG. 1 , a prior art suspended ceiling panel system  10  includes a grid formed by a frame member  12 , which may be main beams  30  or cross beams  39  as previously described above. Frame members  12  that form main beam  30  and cross beams  39  are inverted T-shaped members. Ceiling tiles  18  are positioned and supported by the grid formed by frame members  12 . 
     Where frame members  12  are inverted T-shaped members, ceiling panels  18  are installed such that an edge portion of the bottom surface of each ceiling tile rests on a cross bar portion  34  of an inverted T-shaped frame member. Preferably, the cross bar portion is disposed in a plane generally parallel to a plane defined by ceiling panel  18 . Suspended ceiling system  10  also may include lighting fixture  20  and HVAC elements (not shown). Lighting fixture  20  is installed in desired locations in the grid formed by frame members  12 . Each ceiling panel  18  and light fixture  20  is generally about two feet by about two feet in largest footprint, although in an alternate embodiment a rectangular shaped footprint of about two feet by about four feet in dimension may be used for the ceiling panel and the light fixture. 
     Having now described the structure of prior art suspended ceiling panel system  10 , the installation of the prior art suspended ceiling panel system will now be described below. Frame members  12  are attached to the structure of the building by wires (not show). As set forth above, the wires hang down a distance from the ceiling structure and suspend frame members  12  in a single plane. Ceiling panels  18  are then disposed into frame members  12  in a manner generally well known to those having skill in the relevant art. 
     Prior art suspended ceiling panel system  10  provides noise reduction inside the space below the ceiling panel by allowing sound to pass through the panel, decelerate, then reflect and disperse off the ceiling of the building. This slightly reduces noise in the space below prior art suspended ceiling panel system  10 , but allows the sound to pass through the panels, which creates sound transmission issues. This is especially true when the space above prior art suspended ceiling panel system  10  is used as a plenum return and is open to the surrounding spaces, thereby allowing sound transmitted through the ceiling panel to be transmitted into the adjacent rooms and spaces. 
     As described above, prior art suspended ceiling systems utilize panels  18  that typically are not resistant to bacteria and/or moisture and, therefore, can provide an environment for bacterial infestation and propagation that can potentially lead to discoloration or transmission of the bacterial component into the room. When suspended ceiling panel system  10  is being utilized in an environment that needs to be maintained sterile, such as a hospital operating room or an outpatient surgical operating room, the existence of such a bacterial infestation can be especially problematic. 
     Moreover, prior art suspended ceiling panel system  10  must be adapted for inclusion of HVAC ducts, vents, lights, fire sprinkler systems and the like and therefore requires additional time to install and/or assemble the finished ceiling panel system. 
     In view of this, there remains a need for an improved ceiling panel system that can be utilized in connection with standard inverted T-shaped main beams and cross beams, and which provides accommodation for various ceiling structures such as sprinkler heads, exit signs, heating ventilation and air conditioning ductwork and lights. Moreover, there also remains a need for an improved suspended ceiling panel system that is easy to assemble and has a uniform appearance that is aesthetically pleasing to the eye. Furthermore, there also remains a need for an improved suspended ceiling panel system that provides better insulation characteristics over prior art suspended ceiling panel systems, and which also provides better noise reduction and/or reduces sound transmission through the ceiling panel while still providing fire resistance, bacterial resistance and moisture resistance. 
     These problems are overcome by the suspended ceiling panel system of the present invention, which is described in detail below. 
     A preferred embodiment suspended ceiling panel system of the present invention is shown generally at reference numeral  110  in  FIGS. 2-8  and will now be described in detail below. With particular reference to  FIGS. 2 and 2A , suspended ceiling panel system  110  of the present invention is formed from a plurality of generally square panels  111  having dimensions of approximately two feet by two feet (only a single panel is shown). Panel  111  includes a grid molding  112  located on each of the four sides of the panel. Grid molding  112  is preferably formed from plastic, but may also be formed from other sufficiently rigid material such as metal, alloy, and the like. Grid moldings  112  are mitered at 45 degrees at each of their ends and are attached to one another by a means generally well known in the art, such as by adhesive or thermal welding, to form a generally open-centered square structure. Panel  111  includes a trim molding  114  on each of the four sides of the panel. Trim molding  114  is preferably formed from plastic, but may also be formed from other sufficiently rigid material such as metal, alloy, and the like. Trim moldings  114  are also mitered at 45 degrees at each of their ends and are attached to one another by a means well known in the art, such as by adhesive or thermal welding, to form a generally open-centered square structure. Panel  111  also includes insulation  116  that is disposed into an opening  115  formed by grid moldings  112 . Insulation  116  is preferably a stone wool insulation having an overall thickness equivalent to the height of grid molding  112 . 
     With particular reference to  FIGS. 3-5 , grid molding  112  has a generally C-shaped cross section including a vertical member  138 , a top member  146  and a bottom member  136 . A leg  134  extends generally downwardly from the interior end of bottom member  136 . An interior web  144  is formed near bottom member  136  and extends perpendicularly away from vertical member  138 . Web  144  is equivalent in length to both top member  146  and bottom member  136 . An interior top step  148  is formed at the junction of top member  148  and vertical member  138 . An interior bottom step  142  is formed at the junction of web  144  and vertical member  138 . Insulation  116  is disposed between web  144  and top member  146  and against interior steps  148  and  142  ( FIG. 5 ) to hold the insulation in space in panel  111 . A magnet  122  is disposed between web  144  and bottom member  136 . An LED light  120  is also disposed between web  144  and bottom member  136 . Vertical member  138  of grid molding  112  may optionally be formed with a recess  140  as shown in  FIG. 5 . Recess  140  is only necessary where inverted T-shaped main beam  30  includes top bulb  33 . 
     Trim molding  114  has a generally 9-shaped cross-section rotated 90 degrees and includes an interior vertical member  130  a bottom member  152  and an outer tubular member  150 . Outer tubular member  150  is formed with a square shaped tube  132  into which a metal square-shaped column is disposed. A cloth  118  is disposed over trim moldings  114  and forms a cloth bottom covering for panel  111 . Trim molding interior vertical member  130  rests against leg  134  of grid molding  112  and metal column  124  of the trim molding is attracted to magnet  122  of the grid molding to magnetically hold the trim moldings into place beneath the grid moldings. 
     Optionally, trim molding  114  interior vertical member  130  can be formed with a bulb  128  as shown in  FIG. 8 . In this configuration, leg  134  of grid molding  112  is formed with a socket  126 . Trim molding bulb  128  is disposed into socket  126  to mechanically hold the trim moldings into place beneath the grid moldings. 
     Turning now to  FIGS. 6 and 7 , configurations of panel  111  are shown in exploded view for incorporating airflow ductwork  200 , lighting fixtures  202 , signs  204 , sprinkler heads  206 , exit signs  208  and light panels  210 . Incorporation of the various fixtures is made simple by providing pre-cut insulation inserts  116  that allow passage of the various fixtures through the stone wool insulation. 
     Having now described the structure of suspended ceiling panel system  110  of the present invention, assembly of the ceiling panel system onto a standard inverted T-shaped main beam will now be described in detail below. 
     The grid system including inverted T-shaped main beams  30  and cross beams  39  are assembled in a manner well known to those having skill in the art. In an application where an existing grid system already exists, this step can be eliminated. Grid moldings  112  including insulation are disposed into the grid system with bottom members  136  of the grid moldings resting on flanges  34  of T-shaped main beams  30  and cross beams  39 . Trim moldings  114 , including cloth covers  118  are then mechanically or magnetically fastened onto grid moldings  112  as described above. 
     Suspended ceiling panel system  110  of the present invention accommodates various ceiling structures and/or fixtures, such as sprinkler heads, exit signs, heating ventilation and air conditioning ductwork and lights. Moreover, suspended ceiling panel system  110  of the present invention is easy to assemble and has a uniform appearance following installation that is aesthetically pleasing to the eye. Furthermore, suspended ceiling panel system  110  of the present invention provides better insulation characteristics over prior art suspended ceiling panel systems, such as the one described above, and also provides better noise reduction and/or reduces sound transmission through the ceiling panel better than prior art suspended ceiling panel systems, yet still provides fire resistance, bacteria resistance and moisture resistance. Suspended ceiling panel system  110  of the present invention provides an insulation barrier having an R factor of 8.4. Suspended ceiling panel system  110  of the present invention also provides a noise reduction coefficient of 1 evenly above 100 hertz. Suspended ceiling panel system  110  of the present invention further provides a sound transmission coefficient of approximately  40 . This is accomplished because suspended ceiling panel system  110  of the present invention allows for a full frequency range of sound absorption in the space below the suspended ceiling panel system, but also traps the sound in the panel itself, creating a sound transmission barrier between the adjacent rooms and spaces. 
     Suspended ceiling panel system  110  of the present invention is adapted for use with lighting fixtures, duct work, signs, sprinkler systems, and lighting, yet still provides fire resistance, bacteria resistance, moisture resistance, noise reduction and minimizes noise transfer while remaining aesthetically pleasing to the eye while obscuring the main beams and cross beams of the grid system. Moreover, suspended ceiling panel system  110  of the present invention is easy to install on existing T-shaped main beams and cross beams and still provides a uniform appearance. 
     It is contemplated that the suspended ceiling panel system of the present invention could be utilized in conjunction with other types of grid systems utilizing other than inverted T-shaped main members, without changing the overall concept or operation of the present invention. It is additionally contemplated that other types of ceiling structures and/or fixtures could be utilized in conjunction with the ceiling panel system of the present invention without changing the overall concept or operation of the present invention. Furthermore, it is contemplated that other dimensions of the ceiling panel could be utilized, such as one foot by one foot, or two foot by four foot, without changing the overall concept or operation of the present invention. It is also contemplated that other types of fabric could be used in conjunction with the suspended ceiling panel system of the present invention, without changing the overall concept or operation of the present invention. It is also contemplated that other types of insulation could be utilized in conjunction with the suspended ceiling panel system of the present invention without changing the overall concept or operation of the present invention. 
     Accordingly, the suspended ceiling panel system for residential and commercial buildings of the present invention is simplified, provides an effective, safe, inexpensive and efficient structure and method which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior art system for suspending ceiling panels, and solves problems and obtains new results in the art. 
     In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the present invention has been described with reference to exemplary embodiments. It shall be understood that this illustration is by way of example and not by limition, as the scope of the invention is not limited to the exact details shown or described. Potential modifications and alterations will occur to others upon a reading and understanding of this disclosure, and it is understood that the invention includes all such modifications and alterations and equivalents thereof. 
     Having now described the features, discoveries and principles of the invention, the manner in which the suspended ceiling panel system for residential and commercial buildings of the present invention is used and installed, the characteristics of the construction, arrangement and method steps, and the advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, process, parts and combinations are set forth in the appended claims.