U.S. patent application number 13/367537 was filed with the patent office on 2012-12-20 for self-hanging notched ceiling tile.
This patent application is currently assigned to CHICAGO METALLIC CORPORATION. Invention is credited to Mark A. Fladeland, Weston S. Koennecke.
Application Number | 20120317915 13/367537 |
Document ID | / |
Family ID | 47352581 |
Filed Date | 2012-12-20 |
United States Patent
Application |
20120317915 |
Kind Code |
A1 |
Koennecke; Weston S. ; et
al. |
December 20, 2012 |
Self-Hanging Notched Ceiling Tile
Abstract
A ceiling tile with two pairs of outer straight opposing edges
for a suspended ceiling having a grid with an opening with two
pairs of near-horizontal opposing flanges on which the outer edges
of the tile are supported. Two opposing notches on one of the pair
of edges receive and rest upon one of the pairs of opposing flanges
to vertically hang the ceiling tile.
Inventors: |
Koennecke; Weston S.; (Oak
Park, IL) ; Fladeland; Mark A.; (Bolingbrook,
IL) |
Assignee: |
CHICAGO METALLIC
CORPORATION
Chicago
IL
|
Family ID: |
47352581 |
Appl. No.: |
13/367537 |
Filed: |
February 7, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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29394417 |
Jun 16, 2011 |
D658785 |
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13367537 |
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29394422 |
Jun 16, 2011 |
D658786 |
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29394417 |
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Current U.S.
Class: |
52/506.09 |
Current CPC
Class: |
E04B 9/241 20130101;
E04B 9/366 20130101 |
Class at
Publication: |
52/506.09 |
International
Class: |
E04B 9/18 20060101
E04B009/18 |
Claims
1. A ceiling tile with two pairs of outer straight opposing edges
for a suspended ceiling having a grid with an opening with two
pairs of near-horizontal opposing flanges on which the outer edges
of the tile are supported, comprising: a) two opposing notches on
one of the pair of edges that will receive and rest upon one of the
pairs of opposing flanges to vertically hang the ceiling tile.
2. The ceiling tile of claim 1, wherein the opposing notches are
each substantially equal distant from the other pair of opposing
edges.
3. The ceiling tile of claim 1, wherein the opposing notches are
each close to the other pair of opposing edges.
4. The ceiling tile of claim 1, wherein the opposing notches each
have a wall that is substantially 90.degree. from the one pair of
edges for hanging on the opposing flanges.
5. The ceiling tile of claim 1, wherein the opposing notches each
have a least three adjacent walls with the first wall being
substantially 90.degree. from the one pair of edges for hanging on
the opposing flanges, the second adjacent wall being 90.degree.
from the first wall and the third wall being oblique to the second
wall.
6. The ceiling tile of claim 5, wherein the third wall is greater
than 90.degree. from the adjacent second wall.
7. The ceiling tile of claim 1, wherein the opposing notches each
have at least two adjacent walls with the first wall being
substantially 90.degree. from the one pair of edges for hanging on
the opposing flanges and the second adjacent wall being oblique
from the first.
8. The ceiling tile of claim 1, wherein the opposing notches each
have a tough reinforcement chosen from a group comprising an
extra-heavy coating of paint; a coating of epoxy, a flat adhesive
liner sheet, a paperboard, a plastic, or metal sheet; or a tough
three-dimensional notch insert, all providing a strong, solid
surface that will not easily abrade by contact with a flange.
9. The ceiling tile of claim 1, wherein the tile comprises a
composition chosen from a group comprising vitreous fibers, natural
organic fibers, plastic resins, solid metals and metal alloys,
perforated metals and metal alloys, expanded metals and metal
alloys, woven and welded wire fabrics, or cast minerals, and all
the possible combinations and laminations of these
compositions.
10. A ceiling tile with two pairs of outer straight opposing edges
for a suspended ceiling having a grid with an opening with two
pairs of near-horizontal opposing flanges on which the outer edges
of the tile are supported, comprising: a) two opposing notches on
one of the pair of edges that will receive and rest upon one of the
pairs of opposing flanges to vertically hang the ceiling tile
wherein the opposing notches are each substantially equal distant
from and close to the other pair of opposing edges.
11. The ceiling tile of claim 10, wherein the opposing notches each
have a wall that is substantially 90.degree. from the one pair of
edges for hanging on the opposing flanges.
12. The ceiling tile of claim 10, wherein the opposing notches each
have a least three adjacent walls with the first wall being
substantially 90.degree. from the one pair of edges for hanging on
the opposing flanges, the second adjacent wall being 90.degree.
from the first wall and the third wall being oblique to the second
wall.
13. The ceiling tile of claim 12, wherein the third wall is greater
than 90.degree. from the adjacent second wall.
14. The ceiling tile of claim 10, wherein the opposing notches each
have at least two adjacent walls with the first wall being
substantially 90.degree. from the one pair of edges for hanging on
the opposing flanges and the second adjacent wall being oblique
from the first.
15. The ceiling tile of claim 10, wherein the opposing notches each
have a tough reinforcement chosen from a group comprising an
extra-heavy coating of paint; a coating of epoxy, a flat adhesive
liner sheet, a paperboard, a plastic, or metal sheet; or a tough
three-dimensional notch insert, all providing a strong, solid
surface that will not easily abrade by contact with a flange.
16. The ceiling tile of claim 10, wherein the tile comprises a
composition chosen from a group comprising vitreous fibers, natural
organic fibers, plastic resins, solid metals and metal alloys,
perforated metals and metal alloys, expanded metals and metal
alloys, woven and welded wire fabrics, or cast minerals, and all
the possible combinations and laminations of these
compositions.
17. A ceiling tile with two pairs of outer straight opposing edges
for a suspended ceiling having a grid with an opening with two
pairs of near-horizontal opposing flanges on which the outer edges
of the tile are supported, comprising: a) two opposing notches on
one of the pair of edges that will receive and rest upon one of the
pairs of opposing flanges wherein the opposing notches are each
substantially equal distant from and close to the other pair of
opposing edges. b) a wall in the notch that is substantially
90.degree. from the one pair of edges for vertically hanging the
ceiling tile by the notch on the opposing flanges.
18. The ceiling tile of claim 17, further comprising, another
adjacent wall being oblique to the second wall.
19. The ceiling tile of claim 17, wherein the opposing notches each
have at least two adjacent walls with the first wall being
substantially 90.degree. from the one pair of edges for hanging on
the opposing flanges and the second wall being oblique from the
first.
20. The ceiling tile of claim 17, wherein the opposing notches each
have a tough reinforcement chosen from a group comprising an
extra-heavy coating of paint; a coating of epoxy a flat adhesive
liner sheet, a paperboard, a plastic, or metal sheet; or a tough
three-dimensional notch insert, all providing a strong, solid
surface that will not easily abrade by contact with a flange.
21. The ceiling tile of claim 17, wherein the tile comprises a
composition chosen from a group comprising vitreous fibers, natural
organic fibers, plastic resins, solid metals and metal alloys,
perforated metals and metal alloys, expanded metals and metal
alloys, woven and welded wire fabrics, or cast minerals, and all
the possible combinations and laminations of these compositions.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-in-part of Design patent
application Ser. Nos. 29/394,417 and 29/394,422 both filed on Jun.
16, 2011 respectively for Self-Hanging Tegular Notched Ceiling Tile
and Self-Hanging Square Edge Notched Ceiling Tile.
BACKGROUND OF THE INVENTION
[0002] This invention relates to suspended ceiling systems and more
particularly to ceiling tiles/panels that typically lay-in an
exposed suspended ceiling grid or lattice.
[0003] The grid profile can vary from the standard inverted-T
design in various exposed face widths, to more complicated
bolt-slot (`reveal`) and channel profile (`bandraster`) profiles.
Any grid profile with (most likely horizontal, or near-horizontal)
flanges on which the outer edges of lay-in tiles/panels are
supported will accommodate the use of this invention.
[0004] Above the array in the plenum are located electrical and
computer wiring, ventilation equipment and duct work, lighting
systems, sound systems and an array of other mechanical systems.
Suspended ceilings have the advantage of hiding all of these
mechanical and electrical components.
[0005] Typical appropriate, light-weight tile/panel compositions
include; but are not limited to, vitreous fibers, natural organic
fibers, plastic resins, solid metals and metal alloys, perforated
metals and metal alloys, expanded metals and metal alloys, woven
and welded wire fabrics, cast minerals, gypsum and all the possible
mixtures, combinations, and laminations of the above materials.
[0006] Once the grid profile has been hung from the structural
ceiling by metal straps, threaded rods or wires, the tiles are
removed from their group packaging and one by one are lifted
through a rectangular grid opening at an angle and then are lowered
substantially flat so that their edges catch and lay on the
inwardly extending flanges of the grid.
[0007] From time to time maintenance work must be performed above
the suspended ceiling within the plenum. When a maintenance person
needs to access the plenum area above a suspended ceiling, either
the lay-in ceiling tiles/panels are pushed up into the ceiling and
laid on top of another area of ceiling grid, or the tiles/panels
must be removed from the ceiling and brought down to the lift
platform, scaffolding, floor, tabletop, or other surface for
temporary storage. In either case, the ceiling tiles/panels can be
easily damaged in the process of removal. Tiles that are pushed
into the ceiling plenum can be marred or scratched by being slid
across the grid, or across light fixtures, smoke alarms, and other
mechanical or electrical items attached to other tiles. Plus when
the removed tile is placed on top of other panels and the
previously listed items, the lower aesthetic surface of the removed
tile may become soiled by the dust and dirt that collects on the
upper surface of these other suspended ceiling components. Also,
the edges of tiles can become damaged by accidentally being slid
into grid hanger wires, threaded suspension rods, or other sharp
objects within the plenum.
[0008] Tiles that are removed from the ceiling and brought down to
a lower surface for temporary storage can be damaged during
handling, both during removal and re-installation. The tiles can be
scraped or scratched when passing through the grid opening. They
can be bumped against ladders or lifts, and they can be
accidentally dropped during this removal and transfer process. Once
placed in a temporary storage location, the tiles are subject to
multiple sources of potential damage: personnel and machinery could
run into them; liquids could be spilled, dripped on them, or flood
the surface on which they are placed. The surface on which the
tiles are placed could be dirty and/or oily and could transfer
directly to the aesthetic, visible surfaces of the tiles or could
be transferred during subsequent handling. If placed in an upright
position, on edge, the tiles could fall over or slide down onto the
floor and be walked on or run over by vehicles.
[0009] Also, the process of removing tiles temporarily and placing
them somewhere in the area below the ceiling, and then
re-installing these same panels sometime later requires a great
deal of time to accomplish.
SUMMARY OF THE INVENTION
[0010] A ceiling tile with two pairs of outer straight opposing
edges for a suspended ceiling having a grid with an opening with
two pairs of near-horizontal opposing flanges on which the outer
edges of the tile are supported. Two opposing notches on one of the
pair of edges receive and rest upon one of the pairs of opposing
flanges to vertically hang the ceiling tile.
[0011] A principal object, advantage and feature of the
self-hanging notched ceiling tile is that the notch is designed to
support the ceiling tile in a vertical orientation on the
horizontal flanges of the grid profile when the ceiling tile/panel
is relocated from its normal lay-in horizontal location in order to
gain access to the plenum space above the suspended ceiling.
[0012] Another object and advantage of the notched tile is that
multiples of the notched tile maybe deliberately hung in a vertical
orientation from the grid in a `baffle` arrangement with an
`open-plenum` ceiling design for absorption of undesirable room
noises to create a more quite environment.
[0013] Another object and advantage of the notched tile is that the
feature can be employed in any composition of ceiling tile that is
strong enough that the tile can be supported only along its' outer
edges (by notches) without damage or failure because the tile is
stiff enough that the panel will not excessively deflect or slip
off the flange on the grid.
[0014] Another object and advantage of the notched tile is that the
pair of notches are located close to the upper edge of the
vertically hung tile. By this arrangement, the upper portion of the
tile does not extend beyond the upper limits of grid profile into
the plenum space.
[0015] Another object and advantage of the notched tile, which can
easily be hung from the ceiling grid, is that it will greatly
reduce the potential for overall damage and soiling of the visible
aesthetic surface of the notched tile.
[0016] Another object and advantage of the notched tile is the
significant time savings in the reduced time involved to
temporarily hang the tiles from the grid. This hanging time is much
less than removing them to a temporary storage location below the
ceiling and to place the tiles away from the actual working area.
When hanging the tile by its notches, the aesthetic surface is
faced away from the worker.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of a suspended ceiling with the
notched ceiling tile of the present invention;
[0018] FIG. 2 is another perspective view of a suspended ceiling
with the notched ceiling tile of the present invention;
[0019] FIG. 3 is another perspective view of a suspended ceiling
with the notched ceiling tile of the present invention;
[0020] FIG. 4 is an enlarge perspective view of the suspended
ceiling with the notched ceiling tile of the present invention as
circled in FIG. 3;
[0021] FIG. 5 is front elevational view of a suspended ceiling with
the notched ceiling tile of the present invention;
[0022] FIG. 6 is an enlarge front elevational view of the suspended
ceiling with the notched ceiling tile of the present invention as
circled in FIG. 5;
[0023] FIG. 7 is a top plan view of a notched square edge ceiling
tile broken away;
[0024] FIG. 8 is another top plan view of a notched square edge
ceiling tile;
[0025] FIG. 9 is another top plan view of a notched tegular ceiling
tile;
[0026] FIG. 10 is another top plan view of a notched square edge
ceiling tile;
[0027] FIG. 11 is a perspective view of a suspended ceiling with
the notched ceiling tile of the present invention hung in a
vertical sound baffling arrangement; and
[0028] FIG. 12 is another perspective view of the sound baffling
arrangement of FIG. 13.
DETAILED SPECIFICATION
[0029] Referring to FIGS. 1 through 6, the self-hanging notched
ceiling tile or panel 20 of the present invention may be
appreciated. The Ceiling tile 20 works with a suspended ceiling 2.
Above suspended ceiling tile 20 is the plenum where electrical,
mechanical and air handling equipment is located and to generally
be hidden by the suspended ceiling 2. The ceiling is suspended by
hangers 6 which support and hold the ceiling grid or lattice 8
generally in a horizontal fashion. The grid 8 is an array of
rectangles that have openings 10 therein for placement of the
ceiling tiles 20. The lowermost elements of the grid 8 are
generally rails that are profiled as inverted-Ts 12 with a flange
14 upon which the ceiling tile 20 rests thus hiding the plenum from
view from below thereby rendering an aesthetic view of the
ceiling.
[0030] The ceiling tile 20 typically is square edged or tegular
with a lowered plane rendering a sculptured appearance. The ceiling
tile 20 has a first pair of outer straight opposing edges 22 and a
second pair of outer straight opposing edges 24. These edges 22 and
24 rest upon the flanges 14 of the grid 8 to support the ceiling
panels 20 in an installed fashion. The ceiling panels have a lower
aesthetic face or surface 26 and an upper plenum face or surface 28
that is generally unfinished. However, both faces 26 and 28 may be
finished when the ceiling tiles 20 are desired to be suspended
vertically to create a more open plenum 4 and to create sound
baffles.
[0031] As more clearly seen in FIGS. 4 and 6, the notch 32 has a
first wall 34 that is substantially 90.degree. from the edge 22 or
24 that is bearing the notch 32. A second wall 36 is also
substantially 90.degree. from the first wall 34. This arrangement
assures that ceiling tile 20 securely rests upon flange 14 when a
maintenance worker desires to access the plenum 4. A third wall 38
is oblique from the second wall 36 and typically greater than
90.degree. to assist in guiding the ceiling tile 20 into its
vertically hanging condition. Notches 20 are suitably formed in
either or both edges 22 and 24 generally close and parallel from
the adjoining edges 22 or 24. By this arrangement, tiles 20 do not
protrude into the plenum as to interfere with work being performed
by the maintenance worker as the tile is simply hung from flanges
14 at notches 32.
[0032] The Notch 20 feature suitably may be created by employing a
`hauncher`, which is a machine normally used in the woodworking
industry to produce complicated two-dimensional profiles (shaped
cuts) along the edges of boards or panels. The hauncher employs a
rotating tool with the shape of the feature profile much like a
large router bit. The rotating tool can move through the stationary
tiles 20, or the tiles 20 can move past the stationary rotating
tool. Haunchers are available from Progressive Systems, Inc. of
Anoka, Minn. The notch 20 could also be fabricated by various
methods including; but not limited to, punching, jig-sawing,
routing, water jet cutting, laser cutting or with a hand punch
tool. The specific fabrication method of the notch 20 is often
based on the mechanical properties of the tile 20 composition being
cut.
[0033] Installation of the ceiling tiles 20 of the present
invention is standard in the industry. After the grid 8 has be
securely suspended by hangers 6, the installer removes tiles 20
from their packaging and lifts each tile 20 through an opening 10
at an angle as to clear and not touch the grid flanges 14. The tile
20 is lowered substantially horizontally so that edges 22 and 24
come to rest upon flanges 14 of the grid 8.
[0034] FIGS. 3 through 6 illustrate the vertically hanging of
ceiling tiles 20 for easy, safe and timely access to the plenum 4
for maintenance. FIGS. 3 and 4 show tegular tiles 20 with notch 32
having a first wall 34, a second wall 36 and third wall 38. The
maintenance worker simply lifts the desired tile(s) 20, twists or
rotates the tile 20 and lowers it down into grid opening 10 and
hangs the tile 20 by aligning notches 32 with flanges 14. Ceiling
tiles 20 may have two opposing notches 32 or may have two pair of
opposing notches 32 as is shown. After the work is completed in the
plenum 4, the worker simply lifts ceiling tile 20 off flanges 14,
rotates and lifts the tile 20 up past opening 10 and then
horizontally lowers the tile 20 into horizontal position so that
edges 22 and 24 rest upon flanges 14.
[0035] Based on the required size and location of the notches 32 on
the particular tile 20 and the mechanical properties and
composition of the tile 20, the notches 20 may require different
shapes as shown in FIGS. 7 through 10. FIG. 7 shows a square edge
tile 40 having its notches 42 each having a first wall 44 and a
second wall 46 with reinforcement 48. FIG. 8 shows a square edge
tile 52 having its notches 54 each having a first wall 56 and a
second wall 58 with a plastic reinforcement 60. FIG. 9 shows a
tegular tile 64 having its notches 66 each having a first wall 68,
a second wall 70 and a third wall 72. FIG. 10 shows a square edge
tile 76 having its notches 78 each having a first wall 80, a second
wall 82 and a third wall 84.
[0036] The physical design of the notch is to be shaped such that
when the tile 20 is hanging vertically between two parallel flange
sections 14 of ceiling grid 8, the upper notch wall 34, closest to
the upper edge of the tile, is shaped to conform to the upper
surface of the grid flange 14 which the notch rests upon. For most
cases this upper notch wall 34 will be horizontal; however, special
grid profiles may require other shapes.
[0037] Again, mechanical properties and composition of the tile 40,
may require the notches 42 to have some reinforcement 48. Possible
reinforcements 48 in the notch 40 might include; but are not
limited to, extra-heavy coatings of paint; coatings of epoxy or
other liquids that harden into strong, tough surfaces; flat
adhesive liner sheets (`patches`) on the rear, unexposed surface of
the tile 40 in the area surrounding the notch 42. The reinforcement
liner material 48 could be paperboard, plastic, or metal sheets;
rods, pins, or small bars of metal or plastic driven into the edge
material of the tile 40 just above the notch 42; three-dimensional
notch inserts/liners that fit into the notch and provide a strong,
solid surface. These inserts/liners 48 could be formed, molded, or
cast, they could be metal or plastic, the insert 48 could be held
in place with adhesive or mechanical barbs. The inner notch wall 46
must be vertical and long enough to provide some clearance for ease
of installation when hanging the tile 40 vertically. The distance
between the vertical walls 46 of each side-to-side pair of notches
42 must be precisely maintained to minimize the visibility of the
notches 42 when the tile 40 is installed in its normal lay-in
position on the grid flanges 14. The optional notch third wall
below the vertical wall 46 can be straight or curved as they
connect back to the outer vertical edge of the tile 40. A
rectangular notch is the simplest shape; however custom notches
might be required for special grid profiles or to aid installation
when the tile/panel is being hung vertically.
[0038] FIGS. 11 and 12 show the sound baffling arrangement.
Self-hanging ceiling notched square edge ceiling tiles 20 are
intentionally vertically hung to give a somewhat open plenum look
when looking vertically upward. However from looking at an angle,
the plenum is not visible and the tiles 20 assist in sound
abatement.
[0039] The above embodiments are for illustrative purposes only.
Various other embodiments of the present invention may be
contemplated. The true scope of the present invention is described
in the following claims.
* * * * *