CEILING SYSTEM

Abstract

A ceiling system comprising a plurality of ceiling tiles each comprising a plurality of felt slats. The plurality of felt slats are arranged parallel to one another and include first and second recesses configured to receive and engage a ceiling hanger system.

Claims

1. A ceiling system comprising: a ceiling hanger system comprising a plurality of ceiling hangers arranged in a grid defining a plurality of grid openings, each of the ceiling hangers comprising horizontal flange portions; a plurality of ceiling tiles comprising: a first spacer bar; a second spacer bar; a plurality of felt linear ceiling components coupled to the first and second spacer bars, the felt linear ceiling components being parallel to one another and orthogonal to each of the first and second spacer bars, the first and second spacer bars being spaced from one another, each of the felt linear ceiling components extending from a first end to a second end and comprising: a first recess at least partially defined by a first floor below the first recess and a first roof above the first recess; and a second recess at least partially defined by a second floor below the second recess and a second roof above the second recess; and each of the ceiling tiles mounted to the ceiling hanger systems that: (1) one of the horizontal flange portions of a first one of the ceiling hangers extends into the first recesses of the felt linear ceiling components and engages the first roofs of the first recesses; and (2) one of the horizontal flange portions of a second one of the ceiling hangers extends into the second recesses of the felt linear ceiling components and engages the second roofs of the second recesses.

2. The ceiling system of claim 1 further comprising: wherein the grid formed by the ceiling hangers lies in a first plane; and for each of the ceiling tiles, the felt linear ceiling components comprising a first major surface and a second major surface opposite the first major surface, each of the first and second major surfaces being orthogonal to the first plane.

3. The ceiling system of claim 1 wherein for each of the ceiling tiles, end portions of the felt linear ceiling components extend beneath and partially conceal the horizontal flange portions of the first and second ones of the ceiling hangers.

4. The ceiling system of claim 1 wherein, for each of the ceiling tiles, each of the felt linear ceiling components extend below a bottom side of each of the first and second spacer bars.

5. The ceiling system of claim 1 wherein one of the grid openings is at least partially defined by the first and second ones of the ceiling hangers.

6. The ceiling system of claim 1 wherein for each of the ceiling tiles: each of the felt linear ceiling components extend along a length from the first end to the second end and have a top side, a bottom side, and a width measured from the bottom side to the top side; and at least some of the felt linear ceiling components have a height that varies along the length.

7. The ceiling system of claim 1 further comprising: wherein each of the ceiling hangers is an inverted T-beam; wherein each of the ceiling tiles is mounted to the ceiling hanger system in one of the grid openings to collectively form a ceiling pattern; wherein the grid formed by the ceiling hangers lies in a first plane; wherein for each of the ceiling tiles, the felt linear ceiling components comprising a first major surface and a second major surface opposite the first major surface, each of the first and second major surfaces being orthogonal to the first plane; wherein for each of the ceiling tiles, end portions of the felt linear ceiling components extend beneath and partially conceal the horizontal flange portions of the first and second ones of the ceiling hangers; wherein for each of the ceiling tiles, each of the felt linear ceiling components extend along a length from the first end to the second end and have a top side, a bottom side, and a width measured from the bottom side to the top side, and at least some of the felt linear ceiling components have a height that varies along the length; and wherein, for each of the ceiling tiles, each of the felt linear ceiling component is a felt slat.

8. A ceiling system comprising: a plurality of ceiling tiles, each of the plurality of ceiling tiles comprising: at least one member; a plurality of felt slats coupled to the at least one member so as to be maintained parallel to one another, each of the felt slats comprising: a main body; a first tab comprising a first base portion extending upward from a top side of the main body and a first arm portion extending from the first base portion in a first direction toward a first end of the main body to form a first open recess, the first open recess having a first floor formed by a first portion of the top side of the main body and a first roof formed by an undersurface of the first arm portion; a second tab comprising a second base portion extending upward from a top side of the main body and a second arm portion extending from the second base portion in a second direction opposite the first direction toward a second end of the main body to form a second open recess, the second open recess having a second floor formed by a second portion of the top side of the main body and a second roof formed by an undersurface of the second arm portion; and each of the first and second recesses configured to receive a flange portion of ceiling hangers of a ceiling hanger system to mount the ceiling tile to the ceiling hanger system.

9. The ceiling system according to claim 8 wherein the at least one member is a backer panel.

10. The ceiling system according to claim 8 wherein the at least one member comprises first and second spacer bars.

11. The ceiling system according to claim 8 wherein, for each of the plurality of ceiling tiles, the first and second tabs of each of the plurality of felt slats comprises a tapered upper edge that slopes downward outwardly.

12. The ceiling system according to claim 8 wherein, for each of the ceiling tiles, the main body of each of the felt slats comprises a first vertical major surface and a second vertical major surface opposite the first vertical major surface.

13. The ceiling system according to claim 8 further comprising: the ceiling hanger system comprising a plurality of ceiling hangers arranged in a grid defining a plurality of grid openings; each of the ceiling tiles mounted to the ceiling hanger system so that: (1) the flange portion of a first one of the ceiling hangers extends into the first recesses of the felt slats and engages the first roofs of the first recesses; and (2) a flange portion of a second one of the ceiling hangers extends into the second recesses of the felt slats and engages the second roofs of the second recesses.

14. The ceiling system according to claim 13 wherein for each of the ceiling tiles, end portions of the felt slats extend beneath and partially conceal the flange portions of the first and second ones of the ceiling hangers.

15. A ceiling system comprising: a ceiling hanger system comprising a plurality of ceiling hangers arranged in a grid defining a plurality of grid openings, each of the ceiling hangers comprising flange portions; a plurality of ceiling tiles comprising: a first spacer bar; a second spacer bar; and a plurality of felt slats coupled to the first and second spacer bars, the first and second spacer bars spaced from one another, each of the felt slats comprising: a first tab comprising a first undersurface; and a second tab comprising a second undersurface; the ceiling tiles mounted to the ceiling hanger system in a side-by-side arrangement so that the ceiling tiles collectively form a ceiling pattern, each of the ceiling tiles mounted to the ceiling hanger system by the flange portions of opposing ones of the ceiling hangers engaging the first and second undersurfaces of the felt slats.

16. The ceiling system of claim 15 wherein, for each of the ceiling tiles, each of the felt slats further comprises a main body, the first tab comprises a first arm portion extending in a first direction, and the second tab comprising a second arm portion extending in a second direction opposite the first direction, the first arm portion comprising the first undersurface and the second arm portion comprising the second undersurface; and wherein the ceiling hangers are inverted T-beams.

17. The ceiling system of claim 15 wherein, for each of the ceiling tiles the felt slats are parallel to one another and orthogonal to each of the first and second spacer bars.

18. The ceiling system of claim 15 further comprising: wherein the grid formed by the ceiling hangers lies in a first plane; and wherein for each of the ceiling tiles, the felt slats comprise a first major surface and a second major surface opposite the first major surface, each of the first and second major surfaces being orthogonal to the grid plane.

19. The ceiling system of claim 15 wherein for each of the ceiling tiles, bottom sides of the first and second spacer bars are offset above bottom sides of the felt slats.

20. The ceiling system of claim 15 further comprising: wherein the flange portions of the ceiling hangers lie within a support plane; wherein, for each of the ceiling tiles, the first and second spacer bars are located above the support plane; and wherein, for each of the ceiling tiles, the felt slats are parallel to one another and orthogonal to each of the first and second spacer bars.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIGS. 1 is a perspective view of an acoustic drop ceiling product in accordance with the present disclosure.

[0026] FIG. 2 is a perspective view and the associated cut away view of a prior art standard drop ceiling hanger in accordance with the present disclosure.

[0027] FIGS. 3A through 3C are perspective views of a prior art standard drop ceiling hanger system with installations of four different tiles (FIGS. 3A and 3B) and 16 tiles (FIG. 3C) in accordance with the present disclosure.

[0028] FIGS. 4A through 4D are perspective view (FIG. 4A), plan view (FIG. 4B), side elevation view (FIG. 4C), and front elevation view (FIG. 4D), of a drop ceiling system (Tile A) installed in a prior art standard drop ceiling hanger in accordance with the present disclosure.

[0029] FIGS. 5A through 5D are perspective view (FIG. 5A), plan view (FIG. 5B), side elevation view (FIG. 5C), and front elevation view (FIG. 5D), of a drop ceiling system (Tile B) installed in a prior art standard drop ceiling hanger in accordance with the present disclosure.

[0030] FIGS. 6A through 6D are perspective view (FIG. 6A), plan view (FIG. 6B), side elevation view (FIG. 6C), and front elevation view (FIG. 6D), of a drop ceiling system (Tile C) installed in a prior art standard drop ceiling hanger in accordance with the present disclosure.

[0031] FIGS. 7A through 7D are perspective view (FIG. 7A), plan view (FIG. 7B), side elevation view (FIG. 7C), and front elevation view (FIG. 7D), of a drop ceiling system (Tile D) installed in a prior art standard drop ceiling hanger in accordance with the present disclosure.

[0032] FIGS. 8A and 8B are perspective views of an acoustic drop ceiling product in accordance with the present disclosure.

[0033] FIG. 9 shows perspective views of different tile section types in accordance with the present disclosure.

[0034] FIG. 10 shows a tile section assembly in accordance with the present disclosure.

[0035] FIG. 11 shows a tile section assembly in accordance with the present disclosure.

[0036] FIG. 12 shows a tile section assembly in accordance with the present disclosure.

[0037] FIGS. 13A through 13D shows a tile section installation in accordance with the present disclosure.

[0038] FIG. 14 shows a tile section sample grouping in accordance with the present disclosure.

[0039] FIG. 15 shows a tile section sample grouping in accordance with the present disclosure.

[0040] FIG. 16 is a chart of the acoustic testing in accordance with ASTM C 423 of the drop ceiling product in accordance with the present disclosure.

[0041] FIG. 17 is a graph of the acoustic testing in accordance with ASTM C 423 of the drop ceiling product in accordance with the present disclosure.

DETAILED DESCRIPTION

[0042] As stated herein, the objective of the present disclosure is to provide an improved acoustic drop ceiling product, and an improved dynamic acoustic drop ceiling system, along with improved methods for installing the drop ceiling product on or into a drop ceiling hanger system or t-grid to create the dynamic acoustic drop ceiling system.

[0043] Referring to the drawings, wherein like reference numerals refer to the same or similar features in the various views, FIGS. 1 and 3 through 8 show different views of the improved drop ceiling product 10, tile sections (or tiles) 12 and system 100, which in the preferred embodiment shown in FIG. 1 is a single piece of polyester felt or PET Felt. Each tile section 12 replaces about 24 inches by 24 inches of ceiling space, and each drop ceiling product 10 is about 1 foot, 11 inches long, with varying heights throughout the length to provide the undulating image.

[0044] The drop ceiling product 10 extends from a first end 914 to a second end 915 and generally has two straight sides 14 and a straight top side 16. The bottom side 18, which is seen from the floor when the drop ceiling product 10 or tile section 12 is installed in the ceiling, is either straight or has a curve. When multiple different shaped drop ceiling products 10 are installed in a backer panel (or installed directly onto the ceiling hangers) to create a tile section 12, an undulating image is formed when viewed from the floor.

[0045] The drop ceiling product 10 is made from 9 mm thick PET Felt and comprises one or more installation slots (i.e., tabs) 20, usually two, on the drop ceiling product 10 for installation purposes. Each installation slot/tab 20 has a tapered edge 22 and a recess 24 such that when the drop ceiling product 10 is pushed up into the backer panel 26, the tapered edge 22 will deform and/or move around the backer panel 26 (or the t-grid) and then return to the original shape locked into the backer panel 26. The slots/tabs 20 protrude from the top side 16 of a main body 920 of the drop ceiling product 10. The slots/tabs 20 include a base portion 921 extending upward from the top side 16 of the main body 920 and an arm portion 922 extending from the base portion 921. The recess 24 has a floor 923 formed by a portion of the top side 16 of the main body 921 and a roof 924 formed by an undersurface of the arm portion 922.

[0046] FIG. 2 shows a perspective and side view (A-A) of a standard drop ceiling hanger system 28. The standard drop ceiling hanger 30 is normally configured and sized to hold an acoustic tile (not shown), approximately 2 feet by 2 feet, although different size tiles are available, by laying the tile onto the edges of the hanger 30 in a cantilever arrangement. In doing so, the installed tile blocks the view of the actual ceiling, and in some cases, sprinkler systems and vents (not shown) have to be extended to be accessible to the area below the tile.

[0047] FIG. 3A shows a perspective views of four tiles 12 A, B, C and D being installed into a prior art standard drop ceiling hanger system 28 comprising drop ceiling hangers 30. Each drop ceiling product 10 is combined with other drop ceiling product 10 of the same or different shape to generate a tile section 12 and then a drop ceiling system 100 (FIG. 3C). The drop ceiling product 10 can be installed individually onto the t-grid, or installed onto a backer panel 26 for easier installation onto the drop ceiling hanger system 28.

[0048] FIG. 3B shows the ceiling system 100 partially assembled after installation of tile sections 12 A, B, C and D. Each of the tiles, A through D, are made up of 16 separate acoustic drop ceiling products 10, as an example. The 16 drop ceiling products 10 may each be a different size and shape, or some or all of the products 10 may be the same size and shape, thereby creating different designs. For example, tile A 12 may comprise 16 drop ceiling products 10 of which there are eight sets of two similar size products arranged from maximum depth to minimum depth and back again.

[0049] Tile C 12, on the other hand may have 16 identical drop ceiling products 10, and by combining the different tiles 12, which are made up of the different drop ceiling products 10, an undulating design can be created, and based on the spacing between each drop ceiling product 10, sprinkler systems and vents may not have to be extended.

[0050] FIG. 3C shows the drop ceiling system 100 made up of multiple tile sections 12, which are made up of multiple drop ceiling products 10. Each of the drop ceiling product 10 has been installed (directly or with a backer panel 26) onto the drop ceiling hanger system 28 by using the drop ceiling hangers 30.

[0051] FIGS. 4 through 7 show exemplary tiles 12 A, B, C and D. These tiles 12 are merely examples of the different drop ceiling products 10 that can be used to create the individual tiles 12. For example, FIGS. 4A through 4D include a perspective view (FIG. 4A), plan view (FIG. 4B), side elevation view (FIG. 4C), and front elevation view (FIG. 4D), of the dynamic acoustic drop ceiling tile section A 12, as previously shown in FIG. 3A. Tile A 12 is installed in a prior art standard drop ceiling hanger 30, in accordance with the present disclosure. As exemplified, the drop ceiling products 10 are in the form of slats. The drop ceiling products 10 are coupled to first and second spacer bars 911, 912. The main body 920 of the drop ceiling products 10 comprises opposite major surfaces 925. 926.

[0052] Installed next to tile A 12 is tile B 12, also shown in FIGS. 5A through 5D, which include a perspective view (FIG. 5A), plan view (FIG. 5B), side elevation view (FIG. 5C), and front elevation view (FIG. 5D). The dynamic acoustic drop ceiling tile section B 12, as previously shown in FIG. 3A, is assembled and located next to tile A 12 in the prior art standard drop ceiling hanger 30, in accordance with the present disclosure.

[0053] Likewise, next to tile B 12 is tile C 12, as shown in FIGS. 6A through 6D, and which include a perspective view (FIG. 6A), plan view (FIG. 6B), side elevation view (FIG. 6C), and front elevation view (FIG. 6D). The dynamic acoustic drop ceiling tile C 12, as previously shown in FIG. 3A, is assembled and located next to tile B 12 in the prior art standard drop ceiling hanger 30 in accordance with the present disclosure.

[0054] Finally, next to tile C 12 is tile D 12, as shown in FIGS. 7A through 7D, and which include a perspective view (FIG. 7A), plan view (FIG. 7B), side elevation view (FIG. 7C), and front elevation view (FIG. 7D). The dynamic acoustic drop ceiling tile D 12, as previously shown in FIG. 3A, is assembled and located next to tile C 12 in the prior art standard drop ceiling hanger 30 in accordance with the present disclosure. Together, these four tile sections 12 create an undulating design as seen from the floor of the room.

[0055] As also shown in FIG. 3C, the tile sections 12 A, B, C and D can be repeated continuously throughout the room to continue the undulating design effect and to create the drop ceiling system 100.

[0056] FIGS. 8A and 8B show top and bottom perspective views, respectively, of an embodiment to the present disclosure that includes a backer panel or tile cap 26. The backer panel 26 can also be made of felt, similar to the drop ceiling product 10 disclosed herein. Each of the drop ceiling product 10 can be installed into the backer panel 26, as described herein, thereby intersecting with the drop ceiling product 10 of the tile sections 12 to provide additional acoustic dampening and further blocking the view of the ceiling. Of course, the backer panel 26 may be made of other materials.

[0057] In an alternative embodiment, there can be four types of tile section 12 A, B, C and X to make up a drop ceiling system 100. FIG. 9 shows these four tile section 12 types, with type A 12 using various drop ceiling product 10 to have a tile section that shows undulating on one side 32, to undulating on the other side 34. Tile section B 12 uses various drop ceiling product 10 to create a tile section 12 that undulates on one side 36 and is flat or straight on the other side 38. Tile section C 12 uses the straight drop ceiling product 10 to create a tile section 12 that is straight or flat on both sides 40. Tile section X 12 does not use any drop ceiling product 10. These last tile sections 12 are used on boundary conditions and have no pattern. Using these tile sections 12 A, B, C and X, a drop ceiling system 100 can be generated by placing similar sides together.

[0058] FIG. 10 shows the assembly of a tile section 12 using a backer panel 26 and various drop ceiling product 10. The example shown here is similar to tile section A 12 in which the drop ceiling product 10 goes from undulating on one side 32 to undulating on the other side 34. The two installation slots 20 of each of the 16 drop ceiling product 10 are pushed through the indents 42 of the backer panel 26 until the drop ceiling product 10 is locked into place and rests on the backer panel 26, as shown enlarged in FIG. 11.

[0059] Each drop ceiling product 10 can have a component tag 44, which details which tile section 12 the product 10 is to be installed and where on that tile section 12. For example, the third drop ceiling product on the tile section A1 may have a component tag 44 that reads A1-3.

[0060] Once all of the drop ceiling product 10 have been inserted into the backer panel 26, such that the installation slots 20 have pushed through the backer panel indents 42, the tile section 12 will look like FIG. 12 from above. The tile section 12 is now ready to be installed onto the t-grid or drop ceiling hanger system 28.

[0061] FIGS. 13A through 13C show the tile section 12 installation onto the drop ceiling hangers 30 (which are exemplified in the form of inverted T-beams having horizontal flange portions 931). FIG. 13A shows the tile section 12 placed at an angle so that one edge 46 of the product 10 can slide onto the hanger 30 so that the installation slot 20 will travel over the edge 48 of the hanger 30 (see FIG. 13B). Next the tile section 12 is rotated and popped into place with the installation slot 20 at the opposite edge 50 flexing then snapping back to form over the opposite edge 52 of opposite hanger 30. Once completed, each side and each drop ceiling product 10 will look similar to FIG. 13D, which is an enlargement of FIG. 13C. By installing the tile section 12 in this manner, the outside section of the backer panel 26 can partially or totally obscure from view the bottom side of the hanger 30, for anyone standing on the floor looking up at the ceiling.

[0062] FIGS. 14 and 15 show sample groupings for a drop ceiling system 100 using four tile sections 12, with tiles A1 54 and A2 56, each used twice (FIG. 14), and tiles B1 58, B2 60, B3 62 and B4 64, each used once (FIG. 15). Clearly, numerous tile sections 12 can be generated and therefore numerous designs can be created using a small number of differently shaped products 10.

[0063] As described herein, the material used in the preferred embodiment is polyester felt and is 99% recycled. The ceiling baffles 10 in the preferred embodiment are 9 mm thick, with a standard size of 24 inches by 24 inches, and a maximum size of 24 inches by 48 inches, for 2 by 2 and 2 by 4 drop ceilings, respectively. The edge options are exposed felt, and maintenance includes occasional vacuuming to remove particulate matter and air-borne debris or dust. Compressed air can be used to dust off the material in difficult to reach areas and for large assemblies.

[0064] The felt comes in numerous colors, including white, cream, light grey, light brown, brown, matte grey, charcoal, black, yellow, mango, orange, red, lavender, lime, green, light blue and dark blue. Of course, the ceiling baffles 10 can be manufactured in many other colors and the present disclosure is not limited to these specifications and colors, as these are merely the specifications and colors for the preferred embodiments and alternative embodiments.

[0065] FIG. 16 shows a chart for the acoustic testing standard ASTM C423 for the drop ceiling product 10 in the preferred embodiment. The chart indicates testing on the preferred embodiment and provides the results of the sound absorption coefficient for the drop ceiling product 10 at various frequencies. The test arrangement used a +100 mm air layer filled with 50 mm rock wool board. As described herein, the noise reduction coefficient at 500 Hz 70 is 0.76 66, and at 1000 Hz 74 is 1.00 68. Further, the drop ceiling product 10 is fire rated as UL tested ASTM E-84: Class A.

[0066] FIG. 17 shows the graph 70 of the sound absorption coefficient against frequency for the same test, with the sound absorption average (SAA) 72 of 0.76, and the noise reduction coefficient (NRC) 74 of 0.75.

[0067] Reference throughout the specification to various embodiments, some embodiments, one embodiment, or an embodiment, or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases in various embodiments, in some embodiments, in one embodiment, or in an embodiment, or the like, in places throughout the specification are not necessarily all referring to the same embodiment.

[0068] Further, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features structures, or characteristics of one or more other embodiments without limitation given that such combination is not illogical or non-functional. Although numerous embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this disclosure.

[0069] All directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the any aspect of the disclosure.

[0070] As used herein, the phrased configured to, configured for, and similar phrases indicate that the subject device, apparatus, or system is designed and/or constructed (e.g., through appropriate hardware, software, and/or components) to fulfill one or more specific object purposes, not that the subject device, apparatus, or system is merely capable of performing the object purpose. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.

[0071] Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.