Ceiling system
10288269 ยท 2019-05-14
Assignee
Inventors
Cpc classification
E04B9/18
FIXED CONSTRUCTIONS
E04B9/006
FIXED CONSTRUCTIONS
F21V21/025
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S8/043
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F21V21/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E04B9/12
FIXED CONSTRUCTIONS
E04B9/18
FIXED CONSTRUCTIONS
E04B9/00
FIXED CONSTRUCTIONS
E04B9/06
FIXED CONSTRUCTIONS
Abstract
A ceiling system in one embodiment includes first grid support members arranged in parallel spaced apart relationship. A pair of elongated lighting support members is arranged in parallel with the first grid support members. The lighting support members are spaced apart and define an axially elongated lighting opening. A lighting spacer bracket is connected between and supports the lighting support members from an overhead building support structure. In one embodiment, the bracket is configured to define a downwardly open cavity for at least partially receiving a lighting module therein. A lighting module is positioned in the lighting opening and supported by the lighting support members. In one embodiment, the lighting module may be a digital linear lighting module.
Claims
1. A lighting spacer bracket for supporting a lighting fixture in a ceiling system, the spacer bracket comprising: an elongated body; a substantially horizontal top wall; a first sidewall extending downwardly from the top wall; a second sidewall extending downwardly from the top wall, the first and second sidewalls spaced laterally apart; a mounting extension having a terminal edge and protruding laterally outwards from each of the first and second sidewalls in opposite directions, each mounting extension, having a notch and a hole closer to the terminal edge of the mounting extension than to the opposite sidewall, the top wall and the side walls, configured to engage a lighting support member of a ceiling grid support system; and a downwardly open cavity defined collectively by the top wall, first sidewall, and second sidewall, the cavity configured to receive a lighting module.
2. The lighting spacer bracket according to claim 1, wherein the notch opens downwardly and is configured to engage a vertical edge of one of the lighting support members.
3. The lighting spacer bracket according to claim 1, wherein each mounting extension is configured for insertion through an elongated mounting slot formed through a respective lighting support member.
4. The lighting spacer bracket according to claim 1, wherein the body is formed of a planar plate or sheet of material.
5. The lighting spacer bracket according to claim 1, further comprising stiffening flanges formed on opposing edges of the top wall.
6. The lighting spacer bracket according to claim 1, wherein each mounting extension is further configured for connection to a terminal end of a respective lateral grid support member intersecting a respective one of a pair of the lighting support members.
7. The lighting spacer bracket according to claim 1, wherein the body has a U-shape.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention is best understood from the following detailed description when read in conjunction with the accompanying drawing. It is emphasized that, according to common practice, the various features of the drawing are not to scale. On the contrary, the various features are arbitrarily expanded or reduced for clarity. Included in the drawing are the following figures:
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DETAILED DESCRIPTION
(13) Referring now to the drawing, in which like reference numbers refer to like elements through the various figures that comprise the drawing, a ceiling system is provided which accommodates linear lighting and other similar elongated type lighting fixtures. In some exemplary embodiments, the ceiling system includes lighting support members and lighting spacer brackets which allow for the installation of a linear lighting module without the need for extensive field customization
(14) Referring now to
(15) The longitudinal grid support members 210 and the lateral grid support members 230 are elongated in shape, having a length greater than their respective widths (e.g. at least twice as long). In various embodiments, the longitudinal grid support members 210 and the lateral grid support members 230 have lengths substantially greater than their widths (e.g. three times or more). The longitudinal grid support members 210 may have substantially greater lengths than the lateral grid support members 230 and form runners or rails which are maintained in a substantially parallel spaced apart relationship by the lateral grid support members 230. The lateral grid support members 230 may be attached to and between adjacent (but spaced apart) longitudinal grid support members 210 at appropriate intervals using any suitable permanent or detachable coupling elements. The combination of the interconnected longitudinal grid support members 210 and lateral grid support members 230 provides strength and lateral stability to the overhead grid support system 200. In one non-limiting example, the overhead grid support system 200 may be a Silhouette slotted tee system available from Armstrong World Industries.
(16) In one embodiment, the longitudinal grid support members 210 and the lateral grid support members 230 may be horizontally oriented when installed. It will be appreciated, however, that other suitable mounted orientations of the longitudinal grid support members 210 and the lateral grid support members 230 may be used, such as angled or sloped (i.e. between 0 and 90 degrees to horizontal). Accordingly, although the longitudinal grid support members 210 and the lateral grid support members 230 may be described in one exemplary orientation herein as horizontal, the invention is not limited to this orientation alone and other orientations may be used.
(17) The longitudinal grid support members 210 and the lateral grid support members 230 intersect to form an array of grid openings 206 which receive and are essentially closed by ceiling tiles or panels 208 when positioned within the grid openings 206. In some embodiments, the longitudinal grid support members 210 and the lateral grid support members 230 may be arranged in an orthogonal pattern and intersect at right angles (i.e. perpendicular) to form the grid openings 206 which are rectilinear, such as squares or rectangles (in top plan view). The grid openings 206 are defined by first and second distances D1, D2 which are substantially coextensive with the length and width of the ceiling panels 208 to be installed in the grid openings 206. The ceiling panels 208 may be any type of ceiling panel, including without limitation for example square edge panels, stepped tegular edge panels creating a reveal, or other. The ceiling panels 208 may be constructed of any suitable material or combinations of different materials Some non-limiting examples of ceiling panel materials that may be used include, without limitation, mineral fiber board, fiberglass, metals, polymers, wood, composites, combinations thereof, or other.
(18) Referring to
(19) Similar to the longitudinal grid support members 210, each of the lateral grid support members 230 may be t-shaped in transverse cross section and include a longitudinally-extending horizontal bottom flange 232, an enlarged top stiffening channel 234 (also referred to as a bulb), and a vertical web 236 extending between the bottom flange 232 and the stiffening channel 234. In some embodiments, the stiffening channel 234 may be excluded. The bottom flange 232 has opposing portions which extend laterally outwards from web 236 and terminate in opposed axially extending longitudinal edges 242. The vertical web 236 may be centered between the longitudinal edges 232 and vertically aligned with the centerline CL1 of lateral grid support member 230, or laterally offset from the centerline CL1. The bottom flange 232 also includes a top surface 238 and a bottom surface 240. The bottom surface 240 defines a horizontal ceiling reference plane for the overhead grid support system 200. The top surface 238 provides a surface for positioning and supporting the ceiling panels 208.
(20) Each of the longitudinal grid support members 210 and the lateral grid support members 230 may be made of any suitable metallic or non-metallic materials structured to support the dead weight or load of the ceiling panels 208 without undue deflection. In some non-limiting embodiments, the grid support members may be made of metal including aluminum, titanium, steel, or other. In some non-limiting embodiments, the longitudinal grid support members 210 and the lateral grid support members 230 may be a standard heavy duty 15/16 inch aluminum T-rail having a 15/16 inch grid face or 9/16 inch T-rail having a narrow 9/16 inch grid face.
(21) The longitudinal grid support members 210 may be configured similarly or the same as the lateral grid support members 230, or each may be different. The terminal ends 244 of the lateral grid support members 230 have end connections configured for permanent or detachable connection to the vertical web 216 of one of the longitudinal grid support members 210 at a right angle to form a rectilinear grid pattern (see, e.g.
(22) It will be appreciated that some lateral grid support members 230 may be run the same direction between and parallel to main beam longitudinal grid support members 210, as shown for example in
(23) Each of the longitudinal grid support members 210 and the lateral grid support members 230 defines a respective longitudinal axis LA and axial directions. At least some of the lateral grid support members 230 are arranged perpendicular to the longitudinal axis LA, as in
(24) Features of the overhead grid support system 200 for accommodating lighting fixtures will now be described in further detail. In one embodiment, the lighting fixtures may be linear lighting luminaries or modules 310 which are fully supported solely by the overhead grid support system 200 without supplemental support from the overhead support structure from which the the longitudinal grid support members 210 and the lateral grid support members 230 are suspended. The lighting modules 310 may further be configured for installation entirely from below the grid system, thereby advantageously allowing both initial mounting and replacement without disturbing the grid or ceiling panels.
(25) Referring to
(26) The lighting support members 250 may have any suitable configuration which accommodates the mounting features of the lighting module 310 to properly support the fixture. In one embodiment, two longitudinal grid support members 210 may be used as the lighting support members 250 to form the lighting opening 300 if the lighting module 310 is to be arranged in the same direction as and parallel to the length of the longitudinal grid support members 210 in the ceiling system. The lighting modules 310 will therefore each be axially aligned with the longitudinal axis LA of a respective longitudinal grid support member 210. A width W1 separating the two lighting support members 250 may therefore be less than the normal lateral spacing or width W2 between the longitudinal grid support members 210 in the overhead grid support system 200 not associated with or used for mounting lighting modules 310. It will be appreciated that in other possible layouts of a lighting system for the ceiling system 100, two lateral grid support members 230 may be used as the lighting support members 250 to form the lighting opening 300 if the lighting module 310 is to be to be arranged in a direction perpendicular to the main beam longitudinal grid support members 210.
(27) The terminal ends 252 of the lighting support members 250 may be configured similarly to the terminal ends 244 of the lateral grid support members 230 for engaging the vertical web 236 of a lateral grid support member 230 as shown in
(28) To support the lighting support members 250 due to the lack of lateral grid support members 230 extending through the lighting opening 300 and additional weight of the lighting modules 310, a lighting spacer bracket 400 may be provided. Referring to
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(30) The body 401 of the lighting spacer bracket 400 may be made of a suitable material including metal and non-metal. In one embodiment, the bracket is made of flat metal plate or sheet of material formed to shape, such as without limitation aluminum, titanium, steel, or other. In one implementation, the lighting spacer bracket 400 is made of cold rolled steel which may be coated for corrosion resistance. The thickness T1 is substantially smaller than the lateral width and/or height of the lighting spacer bracket 400. A metal lighting spacer bracket 400 including the stiffening flanges 403 may be formed and machined by any suitable metal fabrication method such as bending, stamping, rolling, forging, casting, cutting, milling, welding, soldering, combinations thereof, and other. A mon-metal lighting spacer bracket 400 may be formed by suitable methods, including without limitation, molding and others.
(31) With continuing reference to
(32) The end portions 432 are further configured to couple to the terminal end 244 of a lateral grid support member 230 (
(33) Referring to
(34) Once the lighting spacer bracket 400 has been mounted to the lighting support members 250, the lighting module 310 may be mounted in the lighting opening 300. The lighting module 310 includes one or more mounting features which allow the lighting module 310 to attach directly to each of the two lighting support members 250 forming lighting opening 300 from beneath the grid support system 200. In one non-limiting implementation, for example, the mounting feature may comprise a spring-loaded depressible latch 312 configured to engage the bottom flange 258 of the lighting support members 250 as best shown in
(35) Any type of lighting modules 310 may be used. In one embodiment, the lighting module 310 may be a zero plenum LED (light emitting diode) linear lighting module such as without limitation a Leno Zero Plenum LED luminaire model N243 available from XAL Inc. These types of fixtures have a height which either does not or only minimally protrudes above the grid members to avoid interference with mechanical or electrical utilities routed through the plenum formed above the grid support system 200. Other types of lighting modules may be used. It will be appreciated that a single or multiple modules may be positioned and supported in each lighting opening 300.
(36) An exemplary method for mounting a lighting module in a ceiling system will now be described with initial reference to
(37) A plurality of longitudinal grid support members 210 that form part of the grid support system 200 are provided and hung from an overhead ceiling support structure using the hanger elements 204. The longitudinal grid support members 210 are arranged in parallel relationship to each other as shown. The longitudinal grid support members 210 are horizontally spaced apart, each defining a longitudinal axis LA. The bottom flange 212 of each longitudinal grid support members 210 substantially lies in a common horizontal reference plane.
(38) Next, two lateral grid support members 230 are installed between, and joined to, a pair of longitudinal grid support members 202 to define a grid opening 206 for the lighting module 310. The two lateral grid support members 230 form the framing headers at each end of the lighting opening 300 in which the lighting module 310 will be installed (see, e.g.
(39) A spaced pair of lighting support members 250 are next positioned and installed within the grid opening 206 in the grid support system 200 where the lighting module 310 is to be located (see, e.g.
(40) Next, lighting spacer brackets 400 are installed between and engage the two lighting support members 250 at right angles. The lighting spacer brackets 400 are installed by inserting the lateral mounting extensions 430 through mounting slots 266 formed in the web 256 of the lighting support members 250. The mounting extensions 430 have a sufficient length to enable the end portions 432 to protrude through the mounting slots 266 sufficiently to enable connection to lighting support members 250 and adjoining lateral grid support members 230 intersecting the lighting support members 250. As the mounting extensions 430 are inserted through the mounting slots 266, the ramp 438 will engage with the top of the mounting slot 266 to force the mounting extension downward to engage the notch 434 and the bottom of the mounting slot 266. The notches 434 in each spacer bracket 400 may be engaged with the mounting slots 266 to hold the brackets in position. The spacer brackets may be further secured to the overhead ceiling support structure by hanger elements 450. A suitable number of lighting spacer brackets 400 may be installed and spaced along the length L1 of the lighting support members 250 as needed to properly support the weight of the lighting support members 250 and the lighting module 310 to be installed between the lighting support members 250.
(41) Each lighting spacer bracket 400 is then preferably connected through the web 256 of lighting support members 250 to a lateral grid support member 230 intersecting the lighting spacer bracket 400 at one terminal end 244 of the intersecting lateral grid support member 230 (see, e.g.
(42) Structurally, it should be noted that pair lighting support members 250 substitute for at least a portion of the total length L2 of the main beam longitudinal grid support members 210. This allows the lighting modules 310 to be oriented along and aligned with the longitudinal axis LA of a longitudinal grid support member 210 as shown in
(43) The lighting installation process continues by horizontally positioning and centering a lighting module 310 beneath the lighting opening 300 defined by the lighting support members 250. The module is then raised and inserted into the opening 300 and secured to the lighting support members 259 via the retractable latches 312 as previously described. Additional lighting modules 310 may be installed in a similar manner if the linear lighting installation is to be formed with multiple modules at this lighting location.
(44) The foregoing process may be repeated to add additional lighting openings 300 and lighting modules 310 to the overhead grid support system 200. It will be appreciated that the foregoing order of steps to install lighting modules 310 may be performed in other orders and/or may include additional or different steps. Accordingly, the installation method is not limited in this regard.
(45) A plurality of additional first lateral grid support members 230 are provided in parallel relationship to each other in the arrangement as shown in
(46) Depending on the size of the ceiling panels 208 and the layout to be created, in some embodiments a second plurality of lateral grid support members 230 may optionally be installed perpendicular to the first plurality of lateral grid support members 230 and arranged parallel to the longitudinal grid support members 210, as shown in the layout of
(47) The intersecting longitudinal and lateral grid support members 202, 204 define the array of grid openings 206 each configured to receive a ceiling panels 208. The grid openings 206 may be rectilinear and are each surrounded by a pair of opposing longitudinally-extending grid faces and a pair of opposing laterally-extending grid faces surface (best shown in
(48) Using the ceiling and lighting support system disclosed herein, various layouts of the lighting modules 310 are possible. For example, in one possible arrangement, the lighting module 310 run may be continuous in one axial direction from wall to wall of the building space (see, e.g.
(49) In the description of embodiments disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as lower, upper, horizontal, vertical,, above, below, up, down, top and bottom as well as derivative thereof (e.g., horizontally, downwardly, upwardly, etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as attached, affixed, connected, coupled, interconnected, and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
(50) The foregoing description of preferred embodiments of the invention should be taken as illustrating, rather than as limiting, the present invention as defined by the claims. As will be readily appreciated, numerous variations and combinations of the features set forth above can be utilized without departing from the present invention as set forth in the claims. Such variations are not regarded as a departure from the spirit and scope of the invention, and all such variations are intended to be included within the scope of the following claims.