Abstract
A ceiling module and method of constructing the same, the ceiling module mountable on a suspended ceiling grid structure and including a plurality of elongate blade members, at least a part of faces of at least two blade members being substantially mutually opposed, at least one elongate cross member extending at least between at least two blade members such that the plurality of blade members are connected to form an arrangement; and at least one support member, releasably engageable with the suspended grid ceiling structure and associated with at least one of the blade members to support the plurality of blade members from the suspended ceiling grid structure.
Claims
1. A ceiling module mountable on a suspended ceiling grid structure, the ceiling module comprising: a plurality of elongate blade members, at least a part of faces of at least two blade members being substantially mutually opposed; at least one elongate cross member extending at least between at least two blade members such that the plurality of blade members are connected to form an arrangement; and at least one support member, releasably engageable with the suspended grid ceiling structure and associated with at least one of the blade members to support the plurality of blade members from the suspended ceiling grid structure.
2. The ceiling module according to claim 1 wherein the blade members each extend substantially parallel to a plane defined by the suspended ceiling grid structure.
3. The ceiling module according to claim 1 wherein the at least one support member is integral with at least one cross member.
4. The ceiling module according to claim 3 wherein the support member extends through the blade members to support the blade members by an interference fit.
5. The ceiling module according to claim 1 including at least one spacing member adapted for locating the blade members in a spaced apart configuration.
6. The ceiling module according to claim 5 wherein the spacing member is integral with at least one cross member.
7. The ceiling module according to claim 6 wherein the spacing member includes blade engaging features adapted for frictionally engaging the blade members.
8. The ceiling module according to claim 1 wherein exposed longitudinal edges of the plurality of blade members provide a decorative visual appearance to the ceiling module when viewed in combination.
9. The ceiling module according to claim 8 wherein at least a portion of at least one cross member contributes to the decorative visual appearance.
10. The ceiling module according to claim 1 including a cover attachable to any one of the blade members, cross members and/or support members and extending across at least a portion of the arrangement.
11. The ceiling module according to claim 1 configured to provide acoustic dampening when installed in the suspended ceiling grid system.
12. The ceiling module according to claim 1 adapted to be installed in proximity to a fixture selected from the group including lights, emergency lights, vents, speakers, smoke detectors or sprinklers.
13. A kit for a ceiling module mountable on a suspended ceiling grid structure, the kit comprising: a plurality of elongate blade members; at least one elongate cross member adapted to extend at least between at least two blade members to connect the blade members such that at least a part of faces of at least two blade members are substantially mutually opposed; at least one support member adapted for releasable engagement with the suspended ceiling grid structure and adapted to be associated with at least one of the blade members to support the plurality of blade members from the suspended grid ceiling structure.
14. The kit according to claim 13 wherein each of the blade members are provided in at least one substantially flat sheet.
15. A method of constructing a ceiling module mountable on a suspended ceiling grid structure, the method including the steps of: providing a plurality of elongate blade members; providing at least one elongate cross member adapted to extend at least between at least two blade members to connect the blade members; providing at least one support member adapted to be releasably engageable with the suspended grid ceiling structure and associated with at least one of the blade members to support the plurality of blade members from the suspended ceiling grid structure; and connecting the blade members to the cross member such that at least a portion of faces of at least two blade members are substantially mutually opposed.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] Preferred embodiment of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:
[0051] FIG. 1A is a partially exploded perspective view of a celling module according to the disclosure;
[0052] FIG. 1B is a side view of the ceiling module of FIG. 1A;
[0053] FIG. 1C is an end view of the ceiling module of FIG. 1A;
[0054] FIG. 2A is a perspective view of three alternative embodiments of a support rail for a ceiling module;
[0055] FIG. 2B is a side view of four embodiments of blade members corresponding to various embodiments of support rails illustrated in FIGS. 1B and 2A;
[0056] FIG. 3 is a perspective view of another embodiment of a ceiling module according to the disclosure;
[0057] FIGS. 4A to 4E are perspective views illustrating a series of assembly steps for assembling a ceiling module according to another embodiment of the disclosure;
[0058] FIGS. 5A to 5F are perspective views illustrating a series of assembly steps for assembling a ceiling module according to another embodiment of the disclosure;
[0059] FIGS. 6A to 6E are perspective views illustrating a series of assembly steps for assembling a ceiling module according to another embodiment of the disclosure;
[0060] FIGS. 7A to 7D are perspective views illustrating creation of a three-dimensional relief within a ceiling module according to another embodiment of the disclosure;
[0061] FIGS. 8A to 8D are perspective views illustrating creation of a three-dimensional relief within a ceiling module according to another embodiment of the disclosure;
[0062] FIG. 9 is a perspective view of a ceiling module according to another embodiment of the disclosure;
[0063] FIG. 10 is a perspective view of a ceiling module according to another embodiment of the disclosure;
[0064] FIG. 11A illustrates a suspended ceiling utilising a plurality of ceiling modules according to another embodiment of the disclosure;
[0065] FIG. 11B is a perspective view of a single ceiling module of the type used in FIG. 11A;
[0066] FIG. 11C is a perspective view of four ceiling modules according to FIG. 11B joined together;
[0067] FIG. 12A illustrates a suspended ceiling utilising a plurality of ceiling modules according to another embodiment of the disclosure;
[0068] FIG. 12B is a perspective view of a single ceiling module of the type used in FIG. 12A;
[0069] FIG. 12C is a front perspective view of the ceiling module of FIG. 12B;
[0070] FIGS. 13A and 13B show a perspective and end view, respectively, of a ceiling module according to another embodiment of the disclosure;
[0071] FIGS. 14A and 14B show a perspective and end view, respectively, of a ceiling module according to another embodiment of the disclosure;
[0072] FIGS. 15A and 15B show a perspective and end view, respectively, of a ceiling module according to another embodiment of the disclosure;
[0073] FIGS. 16A and 16B show a perspective and end view, respectively, of a ceiling module according to another embodiment of the disclosure;
[0074] FIGS. 17A to 17C are perspective, side and end views, respectively, of a ceiling module according to another embodiment of the disclosure where the ceiling module is adapted to engage a lighting fixture;
[0075] FIGS. 18A to 18C are perspective, side and end views, respectively, of a ceiling module according to another embodiment of the disclosure where the ceiling module is adapted to engage a lighting fixture;
[0076] FIGS. 19A to 19C are perspective, side and end views, respectively, of a ceiling module according to another embodiment of the disclosure where the ceiling module is adapted to engage a lighting fixture;
[0077] FIGS. 20A to 20C are perspective, side and end views, respectively, of a ceiling module according to another embodiment of the disclosure where the ceiling module is adapted to engage a lighting fixture;
[0078] FIGS. 21A and 21B are perspective and end views, respectively, of a ceiling module according to another embodiment of the disclosure where the ceiling module is adapted to engage a lighting fixture;
[0079] FIGS. 22A and 22B are perspective and end views, respectively, of a ceiling module according to another embodiment of the disclosure where the ceiling module is adapted to engage a lighting fixture;
[0080] FIGS. 23A and 23B are perspective and end views, respectively, of a ceiling module according to another embodiment of the disclosure where the ceiling module is adapted to engage a lighting fixture; and
[0081] FIGS. 24A and 24B are a perspective view and two end views, respectively, of a ceiling module according to another embodiment of the disclosure where the ceiling module is adapted to engage a lighting fixture.
DETAILED DESCRIPTION
[0082] Referring initially to FIG. 1, the ceiling module 1 includes a plurality of elongate blade members 2, a plurality of cross-members in the form of support rails 3 and spacing members 4, and a cover 5.
[0083] The blade members 2 are arranged such that at the faces of adjacent blade members are mutually opposed and substantially parallel. The blade members 2 are made from porous polymer PET panels. It will be appreciated this material choice is advantageous as the blade members can be manufactured from recycled materials, have sound absorbent qualities and are relatively light weight.
[0084] By suspending the plurality of sound absorbent blade members 2, the ceiling module 1 advantageously provides a large surface area of sound absorbent material relative to the area of the suspended ceiling grid structure occupied by each module. When installed, this has the effect of reducing the reverberant time of an internal or open plan space.
[0085] The support rails 3 extend through blade members 2 and are adapted to be releasably engageable with the suspended ceiling grid structure at each of their ends. As shown in FIG. 1A the rails 3 extend through the blade members 2 in openings in the form of notches 5 at the top edge of the blade members to support the blade members from the suspended ceiling grid structure by an interference fit. The preferred cross-sectional profile for the rails 3 is a dovetail cross section, as illustrated in FIG. 1B. Each blade member 2 has a correspondingly shaped notch 5 for receiving the rail 3 by a sliding fit.
[0086] FIG. 2A illustrates alternative cross-section shapes for the support rail 3 including triangular, circular and square. It will be appreciated that the disclosure is not limited to these examples and that other suitable cross-sectional shapes may be employed.
[0087] FIG. 2B illustrates a number of options for the blade member notch 5. As can be seen, the rail may extend through a notch 5 in top edge of the blade members or, alternatively, through correspondingly shaped openings 5′ in a portion of the blade members adjacent the top edge of the blade members 2.
[0088] FIG. 3 illustrates an alternative embodiment without a support rail, in which support members 3″ are provided in the form of tabs on respective ends of the blade members 2 and cross members 4. It will be appreciated that, in other embodiments, the tabs need not be on all of the blade members 2 and cross members 4 and may instead be present only on select blade members and cross members. Alternatively, tabs may be provided only on select blade members 2, or only on select cross members 4.
[0089] The spacing members 4 extend between the blade members 2 and connect the plurality of blade members 2 to form an arrangement. As is most clearly illustrated in FIGS. 4B, 5C and 6B, the spacing members 4 are in the form of combs having blade-engaging notches 6 evenly spaced along their length. The blade members 2 have corresponding notches 7 along a top longitudinal edge. The notches on the blade members 2 and the notches on the spacing members 4 inter-engage to form a series of halved joints, such that the blade members 2 are evenly spaced apart along the length of the spacing members 4.
[0090] FIGS. 4A to 4E illustrate a series of assembly steps for assembling a ceiling module 1 according to another embodiment of the disclosure from a kit of parts. The kit is provided to the user in a “flat-pack” arrangement and assembled by the user. It will be appreciated that the substantially flat and elongate shape of the blade members 2 and cross members 4 allows them to be produced in a single sheet 8 or a plurality of sheets. This advantageously reduces the costs associated with manufacture and freight, thus allowing the modules to be produced and supplied at a lower price.
[0091] FIG. 4A illustrates a flat sheet of PET material 8, into which the outlines or profiles of shapes defining the blade members 2 and cross members 4 have been cut. The sheet 8 includes a protective surround potion 9 of redundant material which does not form part of the completed module 1 but serves to locate and protect the module components during transport. The blade members 2 and cross members 4 are releasably attached to the protective surround 9 such that they may be removed from the sheet by the end user. FIG. 4A shows one blade member 2 component having been removed from the protective surround 9.
[0092] Once all the components have been removed from the protective surround 9, the blade members 2 and cross members 4 are assembled together to form an arrangement, as shown in FIG. 4B. This is achieved by inter-engaging the respective slots 6 and 7 on the cross members 4 and blade members 2 to form a series of halved joints.
[0093] Where the blade members 2 have differing shapes, they may be connected to the cross members 4 in a pre-determined order to achieve the desired decorative visual appearance of the module. FIGS. 4B and 4C show that, in the illustrated embodiment, the blade members 2 each have a predetermined portion cut away from their exposed longitudinal edge and are connected in a predetermined order to create the impression of an undulating surface.
[0094] As shown in FIG. 4C, the support rails 3 are then slidingly introduced through the aligned notches 5 in the blade members 2. The support rails 3 are positioned such that they extend through across the width of the assembly and have a projecting portion on each side of the assembly for releasably engaging the suspended ceiling grid structure to support the blade members 2 therefrom.
[0095] A cover 10 in the form of a scrim is then attached to the arrangement to cover the arrangement, as shown in FIG. 4D. The cover is attached by a series of fasteners in the form of pins 11 which extend through the cover 10 and into the blade members 2. The cover 10 advantageously obscures a void above the suspended grid ceiling structure from view. In other embodiments, where it is desirable that the void be visible, the cover may be omitted. The cover 10 also advantageously prevents dust or other debris falling from the void space into the area below the suspended ceiling.
[0096] The cover 10 also contributes to the sound absorbing qualities of the module 1. The thickness and material of the cover may be selected to adjust the level of sound absorption.
[0097] FIG. 4E illustrates a completed ceiling module 1, inverted for ease of viewing the details of the blade members 2, support rails 3 and spacing members 4.
[0098] FIGS. 5A to 5F and FIGS. 6A to 6E illustrate assembly processes for two alternative embodiments of a ceiling module according to the disclosure. In these embodiment, each module 1 has four blade members 2 and eight spacing members 4. As can be seen, particularly in FIGS. 5F and 6E, in these embodiments, the spacing members 4 contribute to the decorative visual appearance of the module 1 in combination with the blade members 2.
[0099] In these embodiments, the space between each adjacent blade member 2 is substantially equal to the space between each adjacent spacing member 4 to create a grid or lattice appearance. FIG. 5F illustrates an embodiment wherein the blade members 2 and spacing members 4 have predetermined portions of their exposed longitudinal edges cut away to create the appearance of a series of square profiled tubes extending orthogonally to the plane of the suspended ceiling grid structure. In contrast, FIG. 6E illustrates an embodiment in which the exposed longitudinal edges of the blade members and spacing members are substantially level (apart from the notches 6 and 7), creating the appearance of a grid or lattice defining a substantially flat plane parallel to the plane defined by the suspended ceiling grid structure.
[0100] FIG. 5B shows one method of labelling the blade members 2 and spacing members 4 to indicate the order of assembly to a user. In this embodiment, each blade member 2 and spacing member 4 is labelled with an alpha-numeric character. FIG. 5C shows the blade members 2 and spacing members 4 being assembled in order according to their assigned alpha-numeric characters (for example, 1 to 4 from left to right for the blade members and A to H from back to front for the spacing members) to create the module 1.
[0101] FIGS. 7A to 7D and 8A to 8D illustrate a method of determining the portions of the exposed longitudinal edges of the blade members 2 which are to be cut away to create the appearance of a three-dimensional relief using computer assisted design (CAD).
[0102] FIGS. 7A and 8A, show a set of rectangular blade member 2 profiles. A mould form 12 of a predetermined shape is selected, as shown, for example, in FIGS. 7B and 8B. The desired positioning of the mould form 12 relative to the blade member 2 profiles is then determined, as shown in FIGS. 7C and 8C, and the portions of the blade members 2 lying within the three-dimensional area of the mould form 12 are subtracted from the respective blade member 2 profiles to produce a modified set of blade member 2 profiles as shown in FIGS. 7D and 8D. These modified profile shapes can then be used to produce a physical set of blade members 2 corresponding to the desired design. A similar method may also be applied in respect of spacing members 4. It will be appreciated that this method allows for customization of the shape of each blade member 2 and/or spacing member, and therefore customization of the decorative visual appearance of the ceiling module 1.
[0103] The CAD design process can be completed by a user (typically an architectural specifier or designer) via an online or downloadable interactive digital design tool, reducing the need for third-party input. To achieve this, a standard three-dimensional CAD model template of a ceiling module 1 according to the disclosure is provided to the user. The CAD model is provided with design guidelines, for example, relating to the maximum amount of material that can be removed from the blade members 2 and/or spacing members 4, the minimum shape radius, minimum wall thickness and other similar constraints. The user downloads the standard three-dimensional CAD model and modifies the model using CAD software (for example, using a process similar to that shown in FIGS. 7A to 7D). The user then uploads the modified model. The modified model is then checked, preferably automatically, to ensure that it complies with the design guidance. If the modified model does not comply with the design guidance, the user is provided with non-compliance feedback. Once a design complying with the design guidelines is received, fabrication drawings and optionally a fabrication quote are generated based on the modified model.
[0104] It will be appreciated that the ceiling module 1 of the present disclosure visually enhances suspended ceiling grid systems, and therefore provides an improved room aesthetic. Further the ability to readily customize the appearance of the ceiling module is advantageous as it allows architectural specifiers or designers to incorporate project specific attributes into the ceiling design. This also reduces the likelihood of product substitution by builders.
[0105] FIGS. 9 and 10 show further embodiments of ceiling modules 1 according to the disclosure with alternative blade member 2 shapes.
[0106] FIG. 11A shows a suspended ceiling 13 utilizing a plurality of ceiling modules according to the disclosure to cover the ceiling space. FIG. 11B shows a single ceiling module 1, while FIG. 11C shows four ceiling modules 1 in combination. As can be appreciated, the combination of multiple ceiling modules 1 provides an interesting and distinctive decorative visual effect to the ceiling 13. In the pictured embodiment, the combined ceiling modules 1 create the impression of a woven surface on the ceiling 13. As can be appreciated, the ceiling modules partially conceal the suspended ceiling grid structure from view.
[0107] FIGS. 12A to 12C similarly show the effect of a combination of ceiling modules 1, in this case to create the appearance of a chevron pattern on the ceiling 13.
[0108] The dimensions of the ceiling module 1 can be easily customized to suit the grid structure of the suspended ceiling into which it will be installed. The ceiling modules 1 can easily be removed after installation to gain access to building utilities or services in a void space above the suspended ceiling grid structure.
[0109] FIGS. 13 A and 13B illustrate another embodiment of a ceiling module 1 according to the disclosure, in which the blade members 3 are slanted, or angled, relative to the plane defined by the suspended ceiling grid structure. In this embodiment, the faces of the blade members 2 are all parallel to each other.
[0110] FIGS. 14A and 14B illustrate yet another embodiment of a ceiling module 1 according to the disclosure, in which the blade members 2 are slanted, or angled, relative to the plane defined by the suspended ceiling grid structure. In this embodiment, the blade members 2 are divided into two groups of blade members 2 slanted at opposing angles.
[0111] FIGS. 15A and 15B illustrate yet another embodiment of a ceiling module according to the disclosure, in which the blade members 2 are slanted, or angled, relative to the plane defined by the suspended ceiling grid structure. In this embodiment, the angle of the blade members 2 alternates between adjacent blade members such that the faces of every second blade member are parallel with each other.
[0112] FIGS. 16A and 16B illustrate yet another embodiment of a ceiling module according to the disclosure, in which the faces of the blade members 2 are orthogonal to the plane defined by the suspended ceiling grid structure. The faces of adjacent blade members 2 are opposed and parallel. In this embodiment, a secondary elongate member 14 is provided between each adjacent pair of blade members and extends parallel to the blade members 2.
[0113] It will be appreciated that the disclosure is not limited to the example embodiments illustrated in FIGS. 13A to 16B. It will be apparent to those skilled in the art that the examples provided are by no means exhaustive and that the many other arrangements of blade members are possible within the scope of the present disclosure. It will be appreciated that the customizability of the present disclosure is advantageous in providing choice to architects, builders, interior designers or other such persons.
[0114] FIGS. 17A to 24B illustrate various embodiments of ceiling modules according to the disclosure adapted to engage a lighting fixture 15. It will be appreciated that the disclosure is not limited to these examples and that the ceiling module may be configured to be installed in proximity to and/or engage with light fixtures, or other fixtures such as smoke alarms, vents, fans, sprinklers or similar, in other ways.
[0115] FIGS. 17A, 17B and 17C illustrate another embodiment of a ceiling module according to the disclosure in which the blade members 2 are configured to collectively define a cavity 16 for receiving a light fitting 15, such as an LED strip light. In the illustrated embodiment, a single light strip 15 is provided and the light is partially concealed from view.
[0116] FIGS. 18A, 18B and 18C illustrate another embodiment of a ceiling module 1 according to the disclosure in the ceiling modules 1 is adapted to receive a plurality of LED lighting strips 15.
[0117] FIGS. 19A, 19B and 19C illustrate another embodiment of a ceiling module according to the disclosure in which the ceiling module is adapted to receive a plurality of lighting strips 15 within a respective plurality of cavities 16 defined by the collective blade members 2 such that the lighting strips 15 are partially concealed from view.
[0118] FIGS. 20A, 20B and 20C illustrate another embodiment of a ceiling module 1 according to the disclosure in which the ceiling module is adapted to receive a plurality of lighting strips 15 and wherein the blade members 2 are configured such that the lighting strips 15 are exposed to view.
[0119] FIGS. 21A and 21B illustrate another embodiment of a ceiling module 1 according to the disclosure in which the ceiling module is adapted to receive lighting strips 15 between the blade members 2, secured to the spacing members 4.
[0120] FIGS. 22A and 22B illustrate another embodiment of a ceiling module 1 according to the disclosure in which the ceiling module is adapted to receive lighting strips 15 along the exposed longitudinal edges some of the blade members 2.
[0121] FIGS. 23A and 23B illustrate another embodiment of a ceiling module 1 according to the disclosure in which the ceiling module is adapted to be installed in proximity to a downlight 15, or other light fixture, secured above the ceiling module 1. The blade members 2 and cover 5 are each configured such that the downlight 15 is visible through the module.
[0122] FIGS. 24A and 24B illustrate another embodiment of a ceiling module 1 according to the disclosure in which the ceiling module is adapted to receive lighting strips 15 between the blade members 2, secured to the spacing members 4. As shown in the two end views of FIG. 24B, the size and/or shape of blade members 2 adjacent the lighting strip 15 may be modified as desired to influence the directionality and intensity of the light emitting from the lighting strips 15.
[0123] Advantageously, the present disclosure provides a light-weight ceiling module adapted for use with conventional suspended ceiling grid structures, the ceiling module having a customizable decorative visual appearance and sound absorbing characteristics.
[0124] Although the disclosure has been described with reference to specific examples it will be appreciated by those skilled in the art that the disclosure may be embodied in many other forms.
[0125] These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
