SUSPENDED CEILING SYSTEM AND METHOD FOR INSTALLING THEREOF

Abstract

A suspended ceiling system (1) comprising a plurality of ceiling tiles and a grid (100) of profiles (40) for supporting the plurality of ceiling tiles, the grid (100) of profiles (40) comprising at least a first and a second profile (40) configured to be interconnected along a longitudinal axis, the first and second profile (40) each comprising two laterally extending flanges (43) and an upstanding web (44) provided with a bulb (41) at its free end, wherein each of the first and second profile (40) has a curved extension and is configured to be installed such that it, in an installed and unloaded condition, bulges in an upward direction.

Claims

1. A suspended ceiling system comprising a plurality of ceiling tiles and a grid of profiles for supporting the plurality of ceiling tiles, the grid of profiles comprising at least a first and a second profile configured to be interconnected along a longitudinal axis, the first and second profile each comprising two laterally extending flanges and an upstanding web provided with a bulb at its free end, wherein each of the first and second profile has a curved extension and is configured to be installed such that it, in an installed and unloaded condition, bulges in an upward direction, the suspended ceiling system further comprising a connection element arranged for mounting over a portion of the bulbs of the first and second profile at a joint between the first and second profile, and a suspension element connectable to the connection element for suspension of the first and second profile in their interconnected state.

2. The suspended ceiling system according to claim 1, wherein the connection element is arranged for snap fit mounting over the portion of the bulbs of the first and second profile.

3. The suspended ceiling system according to claim 2, wherein the connection element comprises two resilient legs which for said snap fit mounting are configured to straddle and retain the portion of the bulbs of first and second profile.

4. The suspended ceiling system according to claim 3, in which the connection element comprises a bridging section having a first side from which the two resilient legs extend; and a protruding section provided with an opening arranged on a second side, opposing the first side, of the bridging section, wherein the suspension element is configured to connect to the connection element by means of said opening.

5. The suspended ceiling system according to claim 1, wherein the connection element comprises a protruding section provided with an opening and wherein the suspension element is configured to connect to the connection element by means of said opening.

6. The suspended ceiling system according to claim 5, in which the suspension element comprises a hook member, wherein the opening of the protruding section is configured to receive the hook member for connection of the suspension element to the connection element.

7. The suspended ceiling system according to claim 5, in which the suspension element comprises a free end provided with an opening, wherein the suspension element is connectable to the connection element by means of a fastener inserted into the openings of the suspension element and the protruding section when the openings are aligned with each other.

8. The suspended ceiling system according to claim 1, wherein the connection element is made of a sheet metal material.

9. The suspended ceiling system according to claim 1, wherein each of the first and second profile has a joint end provided with a tongue arrangement, wherein the tongue arrangements of the first and second profile are configured for interlocking engagement in the interconnected state of the first and second profile.

10. The suspended ceiling system according to claim 1, wherein the first and second profile are configured to be interconnected solely by means of the connection element.

11. The suspended ceiling system according to claim 1, wherein the first and second profile, in the loaded and installed condition, are configured to be deflected such that they obtain an essentially linear extension.

12. The suspended ceiling system according to claim 11, wherein the curved extension of the first and second profile is such that the maximum deflection of each profile in the loaded and installed condition is in the range of 5-20 mm.

13. Method for installing a suspended ceiling system comprising plurality of ceiling tiles and a grid of profiles for supporting the plurality of ceiling tiles, the method comprising providing a first and second profile each comprising two laterally extending flanges and an upstanding web provided with a bulb at its free end, wherein each of the first and second profile has a curved extension, interconnecting the first and second profile such that they extend along a longitudinal axis, said interconnecting comprising mounting of a connection element over a portion of the bulbs at a joint between the first and second profile , and suspending the first and second profile by connecting a suspension element to the connection element such that the interconnected first and second profile , in an unloaded condition, each bulges in an upward direction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, with reference to the appended drawings, where the same reference numerals will be used for similar elements, wherein:

[0031] FIG. 1 discloses a perspective view of a suspended ceiling system.

[0032] FIG. 2 discloses a close up perspective view of a joint between two profiles of said ceiling system.

[0033] FIG. 3 discloses a perspective view of a connection element.

[0034] FIG. 4 discloses a plan view of a connection element before folding into final shape.

[0035] FIG. 5 discloses a side view of a connection element.

[0036] FIG. 6 discloses a view along the longitudinal axis of a grid profile.

[0037] FIG. 7 discloses a plan view of a suspension element.

[0038] FIG. 8 discloses a schematic outline of a method for installing a suspended ceiling system.

DESCRIPTION OF EMBODIMENTS

[0039] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the invention to the skilled person.

[0040] In FIG. 1, a suspended ceiling system 1 is shown. The ceiling system 100 is intended to be suspended from the ceiling structure and is configured to carry ceiling tiles (not shown) and various equipment, such as lights, cables, ventilation ducts etc., depending on the application at hand. The ceiling system 1 comprises a grid 100 of profiles, the profiles being interconnected such that the grid 100 is formed. The system 1 may comprise profiles of two types; profiles 40 extending in a first direction and transverse profiles 50 extending in a direction perpendicular to the first direction. The profiles 40 are suspended to the ceiling structure by means of a connection element 10 and a suspension element 20 which is fitted in each joint between two profiles 40. The suspension element 20 may be connected to a ceiling mount 30, which may take the shape of a bracket or an angle iron of some sort which allows attachment of the suspension element 20 thereto.

[0041] The transverse profiles 50 are, when used, supported by the profiles 40. The profiles 40, and optionally the transversal profiles 50, are arranged to form the grid 100 which has openings into which the ceiling tiles will fit.

[0042] The ceiling tiles generally functions to provide an appealing appearance to the suspended ceiling system 1, to dampen sound and to hide the ceiling structure and possible building equipment that is arranged above the suspended ceiling system 1. Such ceiling tiles may be formed in many different ways, the teachings herein are not limited to use with any particular type of ceiling tiles. However, in one embodiment, the ceiling tiles may be made of man-made mineral fibre, such as a compressed mineral fibre material. More specifically, the mineral fibre material may be mineral wool, especially glass wool. In addition to the mineral fibre material, the ceiling tiles may comprise a binder. The ceiling tiles may further comprise at least one surface layer.

[0043] As shown in FIG. 1, it is the profiles 40 which are suspended and that thus carries the weight of the tiles, of any possible transversal profiles 50 and of any eventual equipment fitted to the grid 100.

[0044] In order to increase the load carrying capacity of the profiles 40, they are provided with a curved extension and are configured to be installed such that they, in an installed and unloaded condition, bulges in an upward direction. The profiles 40 are also configured such that they in a loaded and installed condition, i.e. in response to a load, such as ceiling tiles, being applied to the profiles, are deflected such to obtain an essentially linear extension. The curved extension of the profiles 40 may be such that the maximum deflection of each profile 40 in the loaded and installed condition is in the range of 5-20 mm, whereby the profiles obtain the essentially linear extension.

[0045] The upwardly curved extension of the profiles will allow greater load to be placed on each profile 40 before it exceeds a certain regulated value for the downward deflection from the essentially linear extension. The deflection value may for example be defined depending on the distance L between the suspension points, for example measured in mm, divided by a factor of 300. I.e. a maximum allowed deflection could be defined as f=L/300. However, according to EN13964 class 3, the maximum deflection allowed is 4 mm, regardless of the distance between the suspension points.

[0046] The profiles 40 are configured to be interconnected such that a first and second profile of said profiles 40 can be attached to each other end to end along the longitudinal axis of the profiles 40. In one embodiment, the connection element 10 is configured to solely interconnect the first and second profile 40. The connection element 10 can thereby serve two purposes in that it not only provides an anchor point from in the joint from which the grid 100 can be suspended, but in that it also structurally connects each adjacent profile 40 in the grid 100.

[0047] Arranging the connection elements 10 in the joints between the profiles 40 is also beneficial in that is reduces the amount suspension elements 20 required for suspending the ceiling system 1. This saves time when installing the system 1, facilitates the installation process and reduces cost of material.

[0048] Further, the reduced amount of suspension elements 20 also reduces the risk of clashing, i.e. that an installation or building structure in the area of the ceiling structure interferes with the desired position of a suspension element.

[0049] In one embodiment, as shown in FIG. 2, each of the first and second profile 40 has a joint end provided with a tongue arrangement 42, the tongue arrangements 42 of the first and second profile 40 are configured for interlocking engagement in the interconnected state of the first and second profile 40. The profiles 40 may thus be held together by the interaction of the tongue arrangement 42 on each profile 40. In this embodiment, the connection element 10 may not necessarily contribute in any greater extend to the connection of the first and second profile 40, but primarily provides an anchor point for connecting the suspension element 20. However, the connection element 10 may be configured provide a more substantial connection effect in addition to or instead of the interlocking effect of tongue arrangements 42 of the profiles 40.

[0050] Each profile 40 is connected to at least two connection elements 10. For prior art solutions, this means that each profile 40 is suspended by components corresponding to two suspension elements and two connection elements. In the context of the present disclosure, every two adjacent profiles 40 shares a connection element 10 and a suspension element 20. This reduces the number of connection elements 10 and suspension elements 20 necessary. Further still, in the context of grid systems with profiles 40 which are curved as explained above, the connection element 10 aligns the ends of two adjacent profiles 40 in the joint between the profiles 40. It also allows usage of the curvature of the profiles 40 over the entire length of the profiles 40, as they are suspended in the ends of the profiles 40.

[0051] FIG. 2 shows the system 1 in FIG. 1 in a close up view where a connection element 10, a thereto connected suspension element 20 and an optional ceiling mount 30 are shown. The suspension element 20 is shown comprising an optional hook member 21. The hook member 21 is in one embodiment configured to interact with an opening 15 of a protruding section 14 of the connection element 10, which is shown in detail in FIG. 3. The opening is configured to receive the hook member 21 for connection of the suspension element 20 to the connection element 10.

[0052] It is also shown in FIG. 2 how the connection element 10 is mounted in a snap fit manner over a portion of the bulbs 41 which are arranged on the profiles 40. The interaction of the connection element 10 and the bulb 41 on the respective adjacent first and second profile 40 securely holds the profiles 40 in place. It should be noted however, that other means for mounting the connection element over the bulbs other than by snap fit mounting is conceivable.

[0053] Turning to FIG. 3, which discloses a detail view of the connection element 10 according to one embodiment. The connection element 10 in the embodiment shown, comprises two resilient legs 11, 12 which for the snap fit mounting are configured to straddle and retain the portion of the bulbs 41 of first and second profile 40. The connection element 10 can thus be mounted simply by pressing the connection element 10 onto the first and second profile 40, the interaction between the legs 11, 12 and the bulbs 41 will securely support the first and second profile 40.

[0054] As can be further seen in FIG. 3, the connection element 10 may comprise a bridging section 13. The bridging section 13 has a first side 16, as can be seen in FIG. 5, from which the two resilient legs 11, 12 may extend. The optional protruding section 14 which is provided with the opening 15 is arranged on a second side 17 of the bridging section 13, which can also be seen in FIG. 5. The second side 17 is opposite the first side 16.

[0055] What is further evident from FIGS. 3 and 4 is that the connection element 10 may be manufactured from sheet metal by means of punching and bending. Manufacturing the connection element 10 out of sheet metal provides benefits in terms of providing the desired resiliency in the material for the legs 11, 12 to be able to flex as necessary for the snap fit mounting to the profile 40. It is also preferred that the connection element 10 is manufactured out of metal, such as stainless steel or galvanized steel, as it must be able to sufficiently well withstand the heat during a potential fire. However, other materials are also considered depending on the application. The connection element 10 could be manufactured from a polymeric material, or from a composite material such as e.g. carbon composite.

[0056] FIG. 4 shows the connection element 10 blank material after punching but before bending into its final shape. As shown, the protruding section 14 may comprise two cut-out portions which are bent to form the protruding section 14, such that the openings 15 in the respective portion are aligned when the connection element 10 is finalized.

[0057] FIG. 5 shows the connection element 10 from the side. The opposite first and second side 16, 17 of the bridging section 13 is shown being formed by the middle portion of the connection element 10. The free end of each leg 11, 12 may comprise a lip section 18. Each lip sections 18 is bent such that it extends at an incline away from the lip section 18 on the opposite leg 11, 12. A wedge shaped recess is thus formed between the two lip sections 18 which facilitates mounting of the connection element 10 over the bulb 41 of the profile 40 such that the legs 11, 12 straddle the bulb 41 in a snap fit manner.

[0058] What is further shown in FIGS. 4 and 5 is that the connection element 10 may comprise locking members 19 which protrude from the free end of each leg 11, 12. The locking members 19 protrude towards the bridging section 13 such that the may form a securing engagement against the bulb 41. In one embodiment shown in FIG. 6, the bulb 41 of each profile 40 comprises a recess or groove 45 into which the locking member 19 will be arranged when the connection element 10 is fitted to the profile 40. The interaction between the locking member 19 and the groove 45 will prevent that the legs 11, 12 of the connection element 10 for some reason unintentionally to be released from the bulb 41.

[0059] In FIG. 6 it is further shown that each profile 40 comprises two laterally extending flanges 43 and an upstanding web 44 which is provided with the bulb 41 at its free end. The profile is preferably made in a roll forming operation out of a sheet blank of metal, for example steel. The sheet blank is fed between successive pairs of rolls that progressively bend, fold and form the sheet blank until the desired shape and cross section of the profile 40 is obtained. A beneficial profile and method for manufacturing the profile can be found in EP 2 562 323 A1. The teachings herein are however not limited to use with profiles being manufactured in any specific way or of any specific material, any profile having the essential features outlined in claim 1 will be suitable for use with the suspended ceiling system 1.

[0060] Turning now to FIG. 7 which shows a suspension element 20 according to one embodiment. In FIG. 7, the suspension element 20 is embodied as a strip of sheet material, preferably out of metal such as steel but other materials are also considered. The suspension element may comprise reinforcing ribs along the length of the element 20. The suspension element 20 may further comprise a free end 22 which is provided with an opening 23. The suspension element 20 is connectable to the connection element 10 by means of a fastener inserted into the openings 23, 15 of the suspension element 20 and the protruding section 14 when the openings 23, 15 are aligned with each other.

[0061] In the embodiment where the protruding section 14 is formed by two cut-out portions, the free end 22 of the suspension element 20 could be configured to be arranged between the two portions of the protruding section 14 and then fastened with the fastener.

[0062] Alternatively, as mentioned above, the suspension element 20 may comprise a hook member 21 configured to cooperate with the opening 15 in the protruding section 14.

[0063] The suspension element 20 may further be provided with an additional opening 24 on the end opposite the free end 22. The additional opening 24 being configured to be attached to the ceiling mount 30 by means of a suitable fastener.

[0064] FIG. 8 shows a schematic outline of a method for installing a suspended ceiling system 1 as described above. The method comprises providing 1001 a first and second profile 40 each comprising two laterally extending flanges 43 and an upstanding web 44 provided with a bulb 41 at its free end. Each of the first and second profile 40 has a curved extension. The profile, as mentioned, does not need to be made from any particular material or by any particular process. The first and second profiles 40 are then interconnected 1002 such that they extend along a longitudinal axis. The interconnecting comprising snap fit mounting of a connection element 10 over a portion of the bulbs 41 at a joint between the first and second profile 40.

[0065] The first and second profiles 40 are then suspended 1003 by connecting a suspension element 20 to the connection element 10 such that the interconnected first and second profile 40, in an unloaded condition, each bulges in an upward direction.

[0066] It will be appreciated that the present invention is not limited to the embodiments shown.

[0067] The connection element may be formed in different ways. For instance, the protruding section need not be formed from bent cut-out portions but may constitute a top portion of a folded sheet metal material, wherein the two legs extend continuously form the top portion.

[0068] Several modifications and variations are thus conceivable within the scope of the invention which thus is exclusively defined by the appended claims.