U.S. patent application number 15/090272 was filed with the patent office on 2016-10-06 for suspended ceiling.
The applicant listed for this patent is Shawn Engberg. Invention is credited to Shawn Engberg.
Application Number | 20160289964 15/090272 |
Document ID | / |
Family ID | 57017353 |
Filed Date | 2016-10-06 |
United States Patent
Application |
20160289964 |
Kind Code |
A1 |
Engberg; Shawn |
October 6, 2016 |
SUSPENDED CEILING
Abstract
A drop ceiling frame construction is provided having a circular
support frame and a plurality of T-shaped frame members radially
disposed from the circular support frame. At least partially
disposed through the circular support frame are components selected
from the group including of a light, a sensor, sprinkler head, a
smoke detector, and a camera.
Inventors: |
Engberg; Shawn; (Cozad,
NE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Engberg; Shawn |
Cozad |
NE |
US |
|
|
Family ID: |
57017353 |
Appl. No.: |
15/090272 |
Filed: |
April 4, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62142003 |
Apr 2, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 9/10 20130101; E04B
9/067 20130101; E04B 9/14 20130101; E04B 9/127 20130101; E04B 9/006
20130101 |
International
Class: |
E04B 9/10 20060101
E04B009/10; E04B 9/04 20060101 E04B009/04; E04B 9/06 20060101
E04B009/06; E04B 9/18 20060101 E04B009/18 |
Claims
1. A drop ceiling frame construction comprising: a circular support
frame; a plurality of T-shaped frame members radially disposed from
the circular support frame; and a ceiling tile defining a straight
edge engaged with one of plurality of T-shaped frame members.
2. The drop ceiling according to claim 1 where in the ceiling tile
defines a curved edge engaged with the circular support frame.
3. The drop ceiling according to claim 1 wherein the circular
support frame has an L-shaped cross-section.
4. The drop ceiling according to claim 1 wherein the circular
support frame has a T-shaped cross-section.
5. The drop ceiling according to claim 1 wherein the circular
support frame is coupled between adjacent straight frame
members.
6. The drop ceiling according to claim 1 wherein the circular
support frame is supported using support wires.
7. The drop ceiling according to claim 1 wherein the circular
support frame is coupled to the T-shaped frame members using a
flange in slot coupling mechanism.
8. The drop ceiling according to claim 1 further comprising a cover
disposed within the circular support frame.
9. The drop ceiling of claim 1 wherein the T-frame member is formed
from a single sheet metal strip.
10. The drop ceiling according to claim 1 further comprising a
component at least partially disposed through the circular support
frame the component selected from the group consisting of a light,
a sensor, sprinkler head, a smoke detector, a camera.
11. Claim 10 where in the component is fixably coupled to the
circular support frame.
12. A drop ceiling frame construction comprising: a first T-shaped
suspended frame member; a second T-shaped suspended frame member
coupled to the first T-shaped frame member at a 90 degree angle; a
curved support frame coupled to both the first and second T-shaped
suspended frame members; and a ceiling tile defining a first
straight edge engaged with the first T-shaped frame members and a
curved surface coupled to the curved support frame.
13. The drop ceiling according to claim 12 where in the ceiling
tile defines a second straight edge engaged with the second
T-shaped support frame. The drop ceiling according to claim 12
wherein the curved support frame has an L-shaped cross-section. The
drop ceiling according to claim 12 wherein the curved support frame
a curved support frame has a first coupling flange defined at a
first end configured to engage the first T-shaped suspended frame
member, and a second coupling flange configured to engage the
second T-shaped suspension frame member.
16. The drop ceiling according to claim 15 wherein the first
T-shaped support frame defines a coupling slot and the first
coupling flange is disposed within the coupling slot.
17. The drop ceiling according to claim 16 wherein the second
T-shaped support frame has a support surface and wherein the second
coupling flange engages the support surface.
18. A drop ceiling frame construction comprising: a curved support
frame member having a radially disposed curved tile support flange
and a body member defining a plurality of coupling slots; a first
plurality of T-shaped frame members; a second plurality of T-shaped
frame members each having a coupling flange coupled to one of the
plurality of coupling slots, wherein said first and second
plurality of T-shaped frame members defining a grid pattern.
19. The drop ceiling frame construction according to claim 18
wherein the curved support frame member is a circular member having
a radially disposed support tile support flange
20. The drop ceiling frame construction according to claim 18
comprising a ceiling tile having a first straight edge coupled to
one of the second T-shaped frame members, said ceiling tile
defining a second curved surface engaged to the radially disposed
curved tile support flange, and a component at least partially
disposed through the circular support frame the component selected
from the group consisting of a light, a sensor, sprinkler head, a
smoke detector, a camera.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/142,003, filed on Apr. 2, 2015. The entire
disclosure of the above application is incorporated herein by
reference.
FIELD
[0002] The present disclosure relates to drop ceiling construction
and, more specifically, to a roll formed members for a drop-ceiling
frame.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
Traditionally, a drop ceiling is constructed from a metal frame in
the form of a matrix of circular support member 10s which are
generally of extruded or roll formed metal. The frame is used to
support acoustic tile panels and light fixtures. Drop ceiling
construction has become popular in office building design as they
provide an architecturally pleasing appearance and provides a space
between the drop ceiling and the structural ceiling for heating and
air conditioning ducts, plumbing, and wiring. Unfortunately, access
to the space between the drop ceiling and the structural ceiling
through the ceiling tile is labor intensive and can damage fire
safety features.
SUMMARY
[0004] This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of
its features. The present invention is directed to a drop ceiling
frame construction which can be roll formed of sheet metal have
predefined curved or circular frame members. These predefined
curved or circular frame members can be coupled between adjacent
straight frame members. The curved and straight members are
supported to the ceiling structure using support rods or wires. A
slot arrangement provides a mechanism of attaching predefined
curved or circular frame members to the frame at any point along
the length of a circular support member forming the frame.
[0005] The predefined curved or circular frame members are formed
by rolling sheet material to form a circular web having a
predetermined radius. Coupling slots or apertures that allow the
coupling of the circular flanges to linear members are formed in
the web prior to or after shaping the web. A circular support
surface is coupled to the when using ben flanges, adhesive, or
flanges. The slots extend in a direction transverse to the radial
axis of the predefined curved or circular frame members. Linear
members radiate from the circular frame and are combined to form a
grid pattern.
[0006] A drop ceiling frame construction is provided having a
circular support frame and a plurality of T-shaped frame members
radially disposed from the circular support frame. A ceiling tile
defining a straight edge engaged with one of plurality of T-shaped
frame members and a curved edge coupled to the circular support
frame. At least partially disposed through the circular support
frame is a component selected from the group including a light, a
sensor, sprinkler head, a smoke detector, and a camera. The
component can be fixably coupled to the circular support frame.
[0007] According to the present teachings, a drop ceiling frame
construction can have a first T-shaped suspended frame member and a
second T-shaped suspended frame member coupled to the first
T-shaped frame member at a 90 degree angle. An T- or L-shaped cross
section curved support frame is coupled to both the first and
second T-shaped suspended frame members. A ceiling tile defining a
first straight edge engaged with the first T-shaped frame members
and a curved surface coupled to the curved support frame. The
ceiling tile defines a second straight edge engaged with the second
T-shaped support frame.
[0008] Further areas of applicability will become apparent from the
description provided herein. The description and specific examples
in this summary are intended for purposes of illustration only and
are not intended to limit the scope of the present disclosure.
DRAWINGS
[0009] The drawings described herein are for illustrative purposes
only of selected embodiments and not all possible implementations,
and are not intended to limit the scope of the present
disclosure.
[0010] For a better understanding of the invention, reference
should be made to the accompanying drawings, wherein:
[0011] FIG. 1 is an isometric view of a predefined curved or
circular frame members coupled to the matrix of T-frame
members;
[0012] FIG. 2 is a bottom view showing the detail at an
intersection between a predefined curved or circular frame members
and a pair of cross members;
[0013] FIGS. 3A and 3B are sectional views taken substantially on
the line 3-3 of FIG. 2;
[0014] FIG. 4 is a sectional view taken substantially on the line
4-4 of FIG. 2;
[0015] FIG. 5 represents an alternate embodiment of the present
teachings; and
[0016] FIG. 6 represents a section of the embodiment shown in FIG.
6.
[0017] Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0018] Example embodiments will now be described more fully with
reference to the accompanying drawings. FIG. 1 is an isometric view
of a predefined curved or circular frame member 10 coupled to the
matrix of linear T-shaped frame members 12 to form the frame of a
drop ceiling 14. The predefined curved or circular frame member 10
is roll formed to a predetermined radius from a single layer of
metal sheet or folded a longitudinal strip of sheet metal material,
such as aluminum or steel. The members can be roll formed into any
desired length by conventional roll forming techniques.
[0019] The curved 10 and linear T-shaped frame members 12 members
are supported to the ceiling structure using support rods or wires
18. A slot arrangement provides a mechanism of attaching predefined
curved or circular frame members 10 to the linear T-shaped frame
members 12 at any point along the length of a linear T-shaped frame
member 12 forming the frame. Alternatively, the circular frame
members 10 can be located as a central support location at the
intersection of two, three, or four linear T-shaped frame members
12.
[0020] The sheet metal is formed to provide a web section 20 of the
circular frame members 10 consisting of two layers of the sheet
metal normally lying in intimate contact. The upper edge 22 of the
web section 20 can be formed into a deformed channel or box frame
section 24 that strengthens the upper edge 22 of the web section
against lateral bending. Folding the sheet metal to bring the sheet
metal back together to form the two layers of the web sections can
form the section 24.
[0021] At the lower edge of the web section 26, the sheet metal
layers can be bent outwardly and then downwardly to form a
perpendicular ceiling support section. Alternatively, a circular
support surface is coupled to the when using ben flanges, adhesive,
or flanges.
[0022] FIGS. 2-4, show a bottom view showing the detail at an
intersection between a predefined curved or circular frame members
and a pair of cross members shown in FIG. 1. The intersection is
formed by two linear T-shaped frame members 12, which are in axial
alignment with each other and extend perpendicular to the circular
support member 10. As best seen in FIG. 4, the ends of the abutting
cross members 12 and 12' are shaped to fit the cross-sectional
contour of the circular support member 10. Once coupled to the web
portion, the circular support member can have a generally L-shaped
or T-shaped cross section. At the web portion of the circular
support member 10, a vertical slot receives extensions or tongues
that project from the ends of the respective T-shaped frame members
12. The tongues hold the T-shaped frame members 12 in alignment and
at the same time lock the cross members to the circular support
member 10.
[0023] As best seen in FIG. 2, the support sections, for the
circular support member 10, and T-shaped linear frame members 12,
are held in abutting relationship with the edge of the circular
flange sections of the circular support member 10. Thus the
circular support member 10 interrupts and supports the end of the
T-shaped frame members 12. In addition to being supported at the
ends, the T-shaped frame members 12 and circular support member 10
are coupled to the ceiling using drop rods or drop wires.
[0024] Normally square or rectangular ceiling tiles 32 can have a
quarter or half circular cut out defined therein to allow proper
mating with the circular frame 10. The tiles are supported at their
periphery by the support flange of the circular support member 10
and the T-shaped frame members 12.
[0025] As best shown in FIGS. 3 and 4, the slots can be pre-formed
in the sheet metal strip before it is roll formed into the desired
structural shape. The slots extend from the folded outer margin of
the flange sections to the inner deformed or box support section.
The inner layers of the web sections can then be dimpled or crimped
along the length of the slots, to provide additional depth to the
slots for the coupling members of the T-shaped frame members 12 or
the suspension rods or wires.
[0026] By forming the slots prior to the formation of the radius of
curvature, the structural integrity of the circular support member
10 is maintained. At the same time, by removing the outer layer of
the sheet metal in the slots, the surface of the inner layer of the
flange sections is exposed.
[0027] Decorative covers 38 can be placed within the circular frame
10. These decorative covers 38 can be selectively removable from
the circular frame 10. The covers 30 can have engagement surfaces
that selectively engage with surfaces within the circular frame
10.
[0028] FIG. 5 represents an alternate embodiment of the present
teachings where T-shaped frame members 12 are coupled together to
form a grid. Disposed between a pair of perpendicularly engaging
T-shaped frame members 12 is curved frame 10. In this embodiment,
the curved frame represents about 90 degrees of a complete circle.
Four 90 degree curved members can be used to form a circular access
point. Complementary to this structure are four ceiling tiles
having semi-circular cutouts.
[0029] FIG. 6 represents a section of the embodiment shown in FIG.
5. The sectional view shows the coupling mechanism alternate
embodiment of the present teachings where T-shaped frame members 12
are coupled together to form a grid. Disposed between a pair of
perpendicularly engaging T-shaped frame members 12 is curved frame
10. In this embodiment, the curved frame represents about 90
degrees of a complete circle. Four 90 degree curved members can be
used to form a circular access point. Complementary to this
structure are four ceiling tiles having semi-circular cutouts.
[0030] As shown in FIGS. 5 and 6, the drop ceiling frame
construction can have a first T-shaped suspended frame member and a
second T-shaped suspended frame member coupled to the first
T-shaped frame member at a 90 degree angle. A T- or L-shaped cross
section curved support frame is coupled to both the first and
second T-shaped suspended frame members. A ceiling tile defining a
first straight edge engaged with the first T-shaped frame members
and a curved surface coupled to the curved support frame. The
ceiling tile defines a second straight edge engaged with the second
T-shaped support frame.
[0031] As shown in FIG. 5, the curved support frame has a first
coupling flange defined at a first end configured to engage the
first T-shaped suspended frame member, and a second coupling flange
configured to engage the second T-shaped suspension frame member.
The first and second T-shaped support frame members define coupling
slots, where the first coupling flange is disposed within the
coupling slot. At a second end of the curved support frame, the
second T-shaped support frame has support surface where the second
coupling flange engages the support surface.
[0032] Additionally, to prevent rotation of the curved flange, a
surface bears against a side surface of the ceiling tile support
flange. The curved support frame member can represent a full or
partial circle which can be defined around the intersection of
T-shaped members, or can be a centralized circular (See for example
FIGS. 1 and 4.) having a radially disposed curved tile support
flange and a body member defining a plurality of coupling slots.
The T-shaped members have can be divided into a first plurality of
T-shaped frame members and a second plurality of T-shaped frame
members each having a coupling flange coupled to one of the
plurality of coupling slots, wherein said first and second
plurality of T-shaped frame members defining a grid pattern.
[0033] The curved support frame members are a circular member
having a radially disposed support tile support flange. The System
can have a ceiling tile having a first straight edge coupled to one
of the second T-shaped frame members, and the ceiling tile can
defining a second curved surface engaged to the radially disposed
curved tile support flange, and a component at least partially
disposed through the circular support frame the component selected
from the group consisting of a light, a sensor, sprinkler head, a
smoke detector, a camera.
[0034] This intersection construction provides the effect of
continuous intersecting supports while forming a rigid ceiling grid
structure having access to the space above the ceiling tiles. The
foregoing description of the embodiments has been provided for
purposes of illustration and description. It is not intended to be
exhaustive or to limit the disclosure. Individual elements or
features of a particular embodiment are generally not limited to
that particular embodiment, but, where applicable, are
interchangeable and can be used in a selected embodiment, even if
not specifically shown or described. The same may also be varied in
many ways. Such variations are not to be regarded as a departure
from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
[0035] Example embodiments are provided so that this disclosure
will be thorough, and will fully convey the scope to those who are
skilled in the art. Numerous specific details are set forth such as
examples of specific components, devices, and methods, to provide a
thorough understanding of embodiments of the present disclosure. It
will be apparent to those skilled in the art that specific details
need not be employed, that example embodiments may be embodied in
many different forms and that neither should be construed to limit
the scope of the disclosure. In some example embodiments,
well-known processes, well-known device structures, and well-known
technologies are not described in detail.
[0036] The terminology used herein is for the purpose of describing
particular example embodiments only and is not intended to be
limiting. As used herein, the singular forms "a," "an," and "the"
may be intended to include the plural forms as well, unless the
context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of stated features, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. The
method steps, processes, and operations described herein are not to
be construed as necessarily requiring their performance in the
particular order discussed or illustrated, unless specifically
identified as an order of performance. It is also to be understood
that additional or alternative steps may be employed.
[0037] When an element or layer is referred to as being "on,"
"engaged to," "connected to," or "coupled to" another element or
layer, it may be directly on, engaged, connected or coupled to the
other element or layer, or intervening elements or layers may be
present. In contrast, when an element is referred to as being
"directly on," "directly engaged to," "directly connected to," or
"directly coupled to" another element or layer, there may be no
intervening elements or layers present. Other words used to
describe the relationship between elements should be interpreted in
a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the
term "and/or" includes any and all combinations of one or more of
the associated listed items.
[0038] Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of
the example embodiments.
[0039] Spatially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper," and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the Figure s. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the Figure
s. For example, if the device in the Figure s is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above and below. The device may be otherwise
oriented (rotated 90 degrees or at other orientations) and the
spatially relative descriptors used herein interpreted
accordingly.
* * * * *