U.S. patent application number 09/773357 was filed with the patent office on 2002-08-01 for suspended ceiling assembly.
This patent application is currently assigned to INTALITE INC.. Invention is credited to D'agata, Gaetano.
Application Number | 20020100248 09/773357 |
Document ID | / |
Family ID | 25097992 |
Filed Date | 2002-08-01 |
United States Patent
Application |
20020100248 |
Kind Code |
A1 |
D'agata, Gaetano |
August 1, 2002 |
Suspended ceiling assembly
Abstract
A suspended ceiling assembly and method for mounting such an
assembly to provide an inner ceiling suspended under the framework
of a roof. The assembly includes a plurality of suspension beams
suspended in parallel to each other under the framework by cables.
A plurality of mounting rails are mounted transversally underneath
the suspension beams with the help of connecting members. The
connecting members each have a sleeve-shaped body for enclosing a
cross-section of a corresponding suspension beam therein, fasteners
for fastening the sleeve-shaped body to this corresponding
suspension beam, and a hook-shaped bottom portion engageable with
the top flange of a corresponding mounting rail for supporting this
mounting rail. The ceiling tiles are mounted between the bottom
mounting portions of adjacent mounting rails. Advantageously, the
assembly according to this invention is versatile and allows to
easily mount an inner ceiling of a desired shape to any
framework.
Inventors: |
D'agata, Gaetano;
(Pierrefonds, CA) |
Correspondence
Address: |
DARBY & DARBY P.C.
805 Third Avenue
New York
NY
10022-7513
US
|
Assignee: |
INTALITE INC.
|
Family ID: |
25097992 |
Appl. No.: |
09/773357 |
Filed: |
January 31, 2001 |
Current U.S.
Class: |
52/763 ;
52/483.1; 52/745.06 |
Current CPC
Class: |
E04B 9/30 20130101; E04B
9/10 20130101; E04B 9/16 20130101; E04B 9/241 20130101; E04B 9/26
20130101 |
Class at
Publication: |
52/763 ;
52/483.1; 52/745.06 |
International
Class: |
E04B 002/00 |
Claims
What is claimed is:
1. A suspended ceiling assembly for mounting an inner ceiling under
a framework of a roof, the assembly comprising: a plurality of
suspension beams suspendable underneath the framework in a parallel
relationship to each other; a plurality of cables for connecting
the suspension beams to the framework, each of said cable having a
length adapted to suspend a corresponding suspension beam at a
predetermined distance from said framework; a plurality of mounting
rails each transversally mountable underneath at least two of the
suspension beams, each of said mounting rails having a top flange
and a bottom mounting portion; a plurality of connecting members,
each of said connecting members being devised for connecting the
top flange of one of the mounting rails to one of the suspension
beams, each of said connecting member comprising a sleeve-shaped
body for enclosing a cross-section of a corresponding suspension
beam therein, fasteners for fastening said sleeve-shaped body to
said corresponding suspension beam, and a hook-shaped bottom
portion engageable with the top flange of a corresponding mounting
rail for supporting said mounting rail; and a plurality of ceiling
tiles each mountable between the mounting portions of adjacent
mounting rails, for forming said inner ceiling.
2. A suspended ceiling assembly according to claim 1, wherein the
fasteners comprise nuts and bolts.
3. A suspended ceiling assembly according to claim 2, wherein each
suspension beam has a C-shaped cross-section.
4. A suspended ceiling assembly according the claim 1, wherein the
ceiling tiles are made of metal.
5. A suspended ceiling assembly according to claim 1, wherein each
of said mounting rails has an S-shaped cross-section forming a top
hook defining the top flange and a bottom hook defining the
mounting portion.
6. A suspended ceiling assembly according to claim 5, wherein each
ceiling tile comprises: a panel having a back surface and a first
and a second set of two opposed parallel edges; a hooking member
projecting from the back surface of the panel along one of said
parallel edges of the first set and towards said panel, said
hooking member being engageable with the bottom hook of an adjacent
mounting rail; and a first L-shaped member projecting from the back
surface of the panel along another one of said parallel edges of
the first set and away from said panel, said first L-shaped member
being engageable with the hooking member of an adjacent ceiling
tile when said hooking member of an adjacent ceiling tile is
engaged with the bottom hook of one of the mounting rails.
7. A suspended ceiling assembly according to claim 6, wherein: said
hooking member is provided with at least one pin rigidly projecting
therefrom; and said first L-shaped member is provided with at least
one opening therein engageable with the at least one pin of said
hooking member of an adjacent ceiling tile.
8. A suspended ceiling assembly according to claim 6, wherein each
ceiling tile further comprises a first and a second L-shaped side
member each projecting from the back surface of the panel along one
of said parallel edges of the second set and towards said panel,
the first side member being provided with a tab resiliently
projecting therefrom outwardly from the ceiling tile, and the
second side member being provided with a slit adapted to receive
the tab of an adjacent ceiling tile therein when said ceiling tile
and adjacent ceiling tile are mounted between the mounting portions
of adjacent mounting rails.
9. A suspended ceiling assembly according to claim 1, wherein a
number of the plurality of mounting rails each have an I-shaped
cross-section having: a middle portion; a top portion defining said
top flange and forming two top hooks extending on either sides of
the middle portion, each of said top hooks being engageable with
one of the connecting members; and a base portion defining said
bottom mounting portion and forming two bottom hooks for mounting
one of the ceiling tiles thereto, said bottoms hooks extending on
either side of the middle portion.
10. A suspended ceiling assembly according to claim 9, wherein each
ceiling tile comprises: a panel having a back surface and a first
and a second set of two opposed parallel edges; a first and a
second hooking members each projecting from the back surface of the
panel along one of said parallel edges of the first set and away
from said panel, each of the first and second hooking member being
engageable with one of the bottom hooks of an adjacent mounting
rail.
11. A suspended ceiling assembly according to claim 10, wherein
each ceiling tile further comprises a first and a second L-shaped
side member each projecting from the back surface of the panel
along one of said parallel edges of the second set and towards said
panel, the first side member being provided with a tab resiliently
projecting therefrom outwardly from the ceiling tile, and the
second side member being provided with a slit adapted to receive
the tab of an adjacent ceiling tile therein when said ceiling tile
and adjacent ceiling tile are mounted between the mounting portions
of adjacent mounting rails.
12. A suspended ceiling assembly according to claim 1, wherein at
least one of the mounting rails has a C-shaped cross-section
having: a middle portion; a top portion defining said top flange
and forming a top hook extending on one side of the middle portion,
said top hook being engageable with one of the connecting members;
and a base portion defining said bottom mounting portion and
forming a bottom hook for mounting one of the ceiling tiles
thereto, the bottom hook extending on said one side of the middle
portion.
13. A suspended ceiling assembly according to claim 12, wherein
each ceiling tile comprises: a panel having a back surface and a
first and a second set of two opposed parallel edges; a first and a
second hooking members, each projecting from the back surface of
the panel along one of said parallel edges of the first set and
away from said panel, either of the first and second hooking member
being engageable with the bottom hook of an adjacent mounting
rail.
14. A suspended ceiling assembly according to claim 13, wherein
each ceiling tile further comprises a first and a second L-shaped
side member each projecting from the back surface of the panel
along one of said parallel edges of the second set and towards said
panel, the first side member being provided with a tab resiliently
projecting therefrom outwardly from the ceiling tile, and the
second side member being provided with a slit adapted to receive
the tab of an adjacent ceiling tile therein when said ceiling tile
and adjacent ceiling tile are mounted between the mounting portions
of adjacent mounting rails.
15. A method for mounting an inner ceiling under a framework of a
roof, the method comprising steps of: a) suspending a plurality of
suspension beams underneath the framework in a parallel
relationship to each other, a plurality of cables being provided
for connecting the suspension beams to the framework, each of said
cable having a length adapted to suspend a corresponding suspension
beam at a predetermined distance from said framework; b) mounting a
plurality of mounting rails transversally underneath at least two
of the suspension beams, each of said mounting rails having a top
flange and a bottom mounting portion, a plurality of connecting
members being provided for connecting the top flange of each one of
the mounting rails to a corresponding suspension beam, each
connecting member comprising a sleeve-shaped body for enclosing a
cross-section of a corresponding suspension beam therein, fasteners
for fastening said sleeve-shaped body to said corresponding
suspension beam, and a hook-shaped bottom portion engageable with
the top flange of a corresponding mounting rail for supporting said
mounting rail; and c) mounting a plurality of ceiling tiles between
the mounting portions of adjacent mounting rails, thereby forming
said inner ceiling.
16. A method according to claim 15, wherein each mounting rail
mounted in step b) has an S-shaped cross-section forming a top hook
defining the top flange and a bottom hook defining the mounting
portion.
Description
FIELD OF THE INVENTION
[0001] The present invention belongs to the field of suspended
ceilings and more particularly relates to a versatile assembly and
a method for mounting a suspended inner ceiling under the framework
of a roof.
BACKGROUND OF THE INVENTION
[0002] Suspended ceilings are well known in the art. They usually
consist of a flat grid suspended horizontally under the framework
of a roof having square or rectangular shaped holes for receiving
tiles of the same shape. The tiles are supported from every side by
the grid posts, and may usually be removed or displaced by simply
pushing on tiles from underneath.
[0003] Traditional suspended ceilings lack versatility in that they
cannot easily be adapted to define a profile of a different shape
than the flat surface described above. In addition, since the tiles
are supported from underneath, the grid is visible and breaks the
continuity of the design. Also, no means is provided to prevent
access to the space above the suspended ceiling to unauthorized
individuals.
[0004] Improvements in this field are disclosed for example U.S.
Pat. Nos. 4,428,454; 4,566,233; 4,586,841; 4,663,911; 4,833,854;
5,564,250; and 6,029,413. However, none of the devices disclosed in
those patents provide solutions to the above mentioned
drawbacks.
OBJECTS AND SUMMARY OF THE INVENTION
[0005] It is therefore an object of the present invention to
provide a suspended ceiling assembly that allows an inner ceiling
of various profiles to be mounted underneath the framework of a
roof.
[0006] Another object of the invention is to provide a suspended
ceiling assembly for which the beams supporting the ceiling tiles
may be partially or totally hidden.
[0007] Yet another object of the invention is to provide a method
of mounting such a ceiling to the framework of a roof.
[0008] More particularly, the present invention provides a
suspended ceiling assembly for mounting an inner ceiling under a
framework of a roof. The assembly includes a plurality of
suspension beams, which are suspendable underneath the framework in
a parallel relationship to each other. A plurality of cables are
also provided for connecting the suspension beams to the framework.
Each cable has a length adapted to suspend a corresponding
suspension beam at a predetermined distance from the framework. A
plurality of mounting rails are also provided. Each mounting rail
is transversally mountable underneath at least two of the
suspension beams, and has a top flange and a bottom mounting
portion. The assembly includes a plurality of connecting members
each devised for connecting the top flange of one of the mounting
rails to one of the suspension beams. Each connecting member has a
sleeve-shaped body for enclosing a cross-section of a corresponding
suspension beam therein, fasteners for fastening the sleeve-shaped
body to this corresponding suspension beam, and a hook-shaped
bottom portion engageable with the top flange of a corresponding
mounting rail for supporting this mounting rail.
[0009] The assembly finally includes a plurality of ceiling tiles
each mountable between the mounting portions of adjacent mounting
rails, for forming the inner ceiling.
[0010] The invention also provides a method for mounting an inner
ceiling under a framework of a roof. The method includes the steps
of:
[0011] a) suspending a plurality of suspension beams underneath the
framework in a parallel relationship to each other. A plurality of
cables are provided for connecting the suspension beams to the
framework, and each of the cables has a length adapted to suspend a
corresponding suspension beam at a predetermined distance from the
framework;
[0012] b) mounting a plurality of mounting rails transversally
underneath at least two of the suspension beams, each of said
mounting rails having a top flange and a bottom mounting portion. A
plurality of connecting members are provided for connecting the top
flange of each one of the mounting rails to a corresponding
suspension beams. Each connecting member has a sleeve-shaped body
for enclosing a cross-section of a corresponding suspension beam
therein, fasteners for fastening the sleeve-shaped body to this
corresponding suspension beam, and a hook-shaped bottom portion
engageable with the top flange of a corresponding mounting rail for
supporting this mounting rail, and
[0013] c) mounting a plurality of ceiling tiles between the
mounting portions of adjacent mounting rails, thereby forming the
inner ceiling.
[0014] Other features and advantages of the present invention will
be better understood upon reading the following description of
preferred embodiments thereof, with reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a suspended ceiling assembly
mounted underneath the frame work of a roof according to a
preferred embodiment of the invention.
[0016] FIG. 2 is a side elevational view of the assembly of FIG.
1.
[0017] FIG. 3 is a side elevational view of a portion of an inner
ceiling made from an assembly according to another preferred
embodiment of the invention.
[0018] FIG. 4 is a perspective view showing the mounting of two
adjacent ceiling tiles on a mounting rail in accordance with the
embodiment of FIG. 3.
[0019] FIG. 5 is an exploded perspective view of a suspended
ceiling assembly according to the embodiment of FIG. 1.
[0020] FIG. 6 is a side elevation of a portion of an inner ceiling
made from the assembly of FIG. 5.
[0021] FIG. 7A is a side elevation showing the adjacent extremities
of two tiles when one of said tiles is being mounted next to the
other;
[0022] FIG. 7B is a side elevation showing the tile of FIG. 7B when
mounted; and
[0023] FIG. 7C is a side elevation showing how to remove the tiles
of the preceding figures.
[0024] FIG. 8A is a bottom view of an inner ceiling mounted in
accordance with the embodiment of FIG. 3; and FIG. 8B is a bottom
view of an inner ceiling mounted in accordance with the embodiment
of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
[0025] Referring to FIGS. 1 and 2, there is generally shown an
inner ceiling 20 made from a suspended ceiling assembly according
to the present invention. The features of the invention explained
hereinbelow are common to both the first and the second preferred
embodiments of the invention.
[0026] The ceiling 20 includes a plurality of suspension beams 22
suspended underneath the framework 24 of a roof. The suspension
beams 22 all extend in a parallel relationship to each other, but,
as is exemplified in the illustrated embodiment, may be disposed at
different distances from the framework 24. The advantages of such a
set-up will be explained hereinafter. The suspension beams
preferably each have squared C-shaped cross-sections. A plurality
of cables 26 are provided for connecting the suspension beams 22 to
the framework 24. Preferably, the suspension beams 22 each have a
number of hooks 28 projecting therefrom, which may of course be
replaced by any other appropriate fastening means. In the
illustrated embodiments (see for example FIG. 5), the hooks are
embodied by a C-shaped clamp 27 fastened to the suspension beam 22
at any appropriate location and a loop 29 projecting integrally
from the top. and a lower end 30 of each cable 26 is attached to
one of the hooks 28. The upper end 32 of the cables 26 is attached
to wooden beams 34, or any other structural element of the
framework solid enough to support the weight of the inner ceiling
20. The length of each cable 26 between the lower and the upper
ends 30 and 32 is chosen so that the corresponding suspension beam
22 extends at the desired distance from the framework 24.
Advantageously, the use of cables of a given length can also easily
allow to adapt a given assembly to a framework of uneven height, as
best seen in FIG. 2.
[0027] The inner ceiling 20 further includes a plurality of
mounting rails 36. Each mounting rail 36 has a top flange 40 and a
bottom mounting portion 42, and is mounted transversally under two
or more suspension beams 22. A plurality of connecting members 38
are also provided, to connect the mounting rails 36 from its top
flange 40 to the corresponding suspension beams 22. At least one
connecting member 38 is preferably provided at each crossing point
between the mounting rails 36 and suspension beams 22.
Advantageously, the mounting rails 36 may be given a variety of
profiles other than a straight one, as was previously known in the
art. For example, in the illustrated embodiment of FIGS. 1 and 2,
the mounting rails 36 each define an arch section, and the height
of each suspension beam 22 is adjusted accordingly. The inner
ceiling finally includes a plurality of ceiling tiles 44, each
mountable between the mounting portions 42 of adjacent mounting
rails 36.
[0028] Referring to FIG. 5, the connecting members 38 are shown as
preferably having a sleeve-shaped body 46 which completely encloses
a cross-section of a suspension beam 22. The sleeve-shaped body 46
is preferably fitted over the desired section of a suspension beam
22 and fastened thereto with nut 48 and bolt 49 affixed on top of
the connecting member 38, which is provided with an opening therein
for that purpose. Of course, any other appropriate type of
fasteners may be used. The sleeve-shaped body 46 has a hook-shaped
bottom portion 50 which is engageable with the top flange 40 of the
mounting rails 36. Advantageously, the connecting members may be
affixed at any point of the suspension rails 22, making the
assembly of the mounting rails very adaptable to the dimensions and
physical properties of a particular ceiling.
[0029] Description of the First Preferred Embodiment of the
Invention
[0030] With reference to FIGS. 3, 4 and 8A, there is shown a first
preferred embodiment of a suspended ceiling assembly according to
the present invention.
[0031] In this embodiment, each mounting rail 36 has an S-shaped
cross-section forming a top and a bottom hook. The top hook defines
the top flange 40 of the mounting rail, and is therefore engageable
with the hook-shaped bottom portion 50 of the connecting members 38
as best seen in FIG. 3. The bottom hook defines the bottom mounting
portion 42 or the mounting rail 36, and serves to support the
ceiling tiles 44 as explained below.
[0032] In this embodiment, the ceiling tile 44 includes a panel 52
having a back surface 54 and a first 56 and second 58 set of two
opposed parallel edges. In the illustrated embodiment, the panel 52
is rectangular shaped, but tiles having other shapes such as
squares or trapezoids may conceivably be used. A hooking member 60
preferably projects from the back surface 54 of the panel 52, along
one of the edges of the first set 56. The hooking member 60 opens
towards the panel 52 as is better seen in FIG. 4. The hooking
member 60 is engageable with the bottom hook defining the mounting
portion 42 of an adjacent mounting rail 36. On the other side of
the panel 52, along the other edge of the first set 56, a first
L-shaped member 62 projects from the back surface 54 of the panel
52. Contrary to the hooking member 60, the first L-shaped member 62
is oriented away from the panel 52. The side of the panel 52
provided with the first L-shaped member 62 is mounted on the
mounting portion 42 of the mounting rail 36 by engaging the first
L-shaped member 62 with the hooking member 60 of an adjacent
ceiling tile 44 when it is itself engaged with the bottom mounting
portion 42 of one of the mounting rails 36. For this purpose, each
hooking member 60 is provided with at least one pin 64 rigidly
projecting from its top surface, and each first L-shaped member 62
is provided with at least one opening 66 therein engageable with
the pin 64 of the hooking member 60 of an adjacent ceiling tile 44.
An advantage of this pin and opening engagement is that it provides
a means for aligning the ceiling tiles together along their length
(positive alignment).
[0033] Advantageously, as may be seen in FIG. 8A, the inner ceiling
mounted according to the first embodiment, has a continuous
appearance from underneath, since all of the suspension beams or
mounting beams are hidden under the ceiling tiles.
[0034] Description of the Second Preferred Embodiment of the
Invention
[0035] With reference to FIGS. 5, 6 and 8B, there is shown a second
preferred embodiment of the present invention.
[0036] In accordance with this new embodiment, a number of the
mounting rails 36 each have an I-shaped cross-section, including a
middle, a top and a base portion 68, 70 and 72. The top portion 70
defines the top flange 40 of the mounting rail 36, and forms two
top hooks 74 extending on either side of the middle portion 68.
Each of the top hooks 74 is engageable with one of the connecting
members 38, as best seen in FIG. 6. With this type of mounting
rail, two connecting members 38 are preferably provided at each
crossing point between the mounting rails 36 and the suspension
beams 22, one engaged with each top hook 74. Similarly, the base
portion 72 defines the bottom mounting portion 42 and forms two
bottom hooks 76 extending on either side of the middle portion
68.
[0037] The I-shaped mounting rails are well adapted for supporting
the ceiling tiles across most of a given ceiling, but may be
unsightly and interfere with proper placement of the rails at the
edges of the ceiling. There are therefore provided within the
present embodiment a number of mounting rails having a C-shaped
cross-section, adapted to support the ceiling tiles along the edges
of the ceiling. Similarly, the C-shaped rails each have a middle
portion 78, a top portion 80 and a base portion 82. The top portion
defines the top flange 40 and forms a top hook 84 extending on one
side of the middle portion 78, the top hook 84 being engageable
with one of the connecting members 38, and the base portion 82
defines the bottom mounting portion 42 and forms a bottom hook 86
extending on said one side of the middle portion for mounting one
of the ceiling tiles thereto.
[0038] As with the ceiling tile described before, the tiles 44
appropriate for this embodiment also have a panel 52 with a back
surface 54 and a first and a second set of two opposed parallel
edges 56 and 58. In this case two hooking members 88 and 90 are
provided along each of the edges of the first set 56. Each hooking
member projects from the back surface 54 away from the panel 52,
and is engageable with one of the hooks formed by the mounting
portion 36 of an adjacent mounting rail 36.
[0039] In this embodiment, as may be seen in FIGS. 1 and 8B, the
ceiling tiles 44 are mounted in rows and the underside of the
mounting rails is visible from the room provided with such a
ceiling.
[0040] With reference to FIG. 5, there are shown a few additional
features that although applied here to the second embodiment of the
invention, could equally be included in the first or any further
embodiments of the present invention.
[0041] Preferably, rubber pieces 102 are installed at various
positions over the hooks of the bottom mounting portion 42. The
rubber pieces 102 advantageously damper the engagement of the
ceiling tiles with the suspension rails 36 and provide the inner
ceiling with more stability since they prevent the tiles from
rocking.
[0042] Additionally, C-shaped end beams 104 may be transversally
installed at the extremities of the mounting rails 36 to give a
finished look to the transversal edges of the ceiling.
[0043] For manufacturing and transport convenience, each suspension
beam 36 may be made of sections assembled on site, end to end.
Connecting pieces 106 of an appropriate shape are then provided
with nuts and bolts 108 to attach them to the mounting rail
sections.
[0044] Referring to FIGS. 4 and 7A to 7C, there is shown an
additional feature of the invention which may be included in either
one of the embodiments described above. Each ceiling tile 44
preferably includes a first and a second side member 92 and 94,
each being L-shaped and projecting from the back surface 54 of the
panel 52 along one of the edges of the second set 58. Both the
first and second side members 92 and 94 are oriented towards the
panel 52, similarly to the hooking member 60. The first side member
92 has a tab 96 resiliently projecting therefrom, outwardly from
the ceiling tile 44 (FIG. 7A). The second side member 94 is
provided with a slit 98 adapted to receive the tab 96 of an
adjacent ceiling tile therein (FIG. 7B). This feature has several
advantages. It allows the ceiling tiles to be aligned with each
other and to be suspended all at the same height. In addition, once
two tiles are locked together in this manner, it is impossible to
remove one of them without using a proper tool 100 to push the tab
96 out of the slit 98 as shown in FIG. 7C.
[0045] Description of a Method According to the Invention
[0046] In accordance with a preferred embodiment of the invention,
there is also provided a method for mounting an inner ceiling under
a framework of a roof as shown in FIG. 1. This method includes the
following steps of:
[0047] a) suspending a plurality of suspension beams 22 underneath
the framework 24 in a parallel relationship to each other. A
plurality of cables 26 are provided for connecting the suspension
beams 22 to the framework 24. Each of the cables 26 has a length
adapted to suspend a corresponding suspension beam 22 at a
predetermined distance from the framework 24;
[0048] b) mounting a plurality of mounting rails 36 transversally
underneath at least two of the suspension beams 22. Each mounting
rail 36 has a top flange and a bottom mounting portion and may have
an S-shaped, I-shaped or C-shaped cross-section as described above.
A plurality of connecting members 38 are provided for connecting
the top flange of each one of the mounting rails 36 to a
corresponding suspension beam 22. Preferably, each connecting
member 38 includes a sleeve-shaped body for enclosing a
cross-section of a corresponding suspension beam 22 therein,
fasteners for fastening them together and a hook-shaped bottom
portion engageable with the top flange of a corresponding mounting
rail 36; and
[0049] c) mounting a plurality of ceiling tiles 44 between the
mounting portions of adjacent mounting rails 36, thereby forming
the inner ceiling 20.
[0050] Of course, numerous modifications could be made to the
embodiments described above without departing from the scope of the
invention as defined in the appended claims.
* * * * *