Abstract
A ceiling system comprising a ceiling tile comprising a backer panel and a plurality of ceiling components assembled to the backer panel is disclosed. The ceiling components include connectors that pass through openings in the backer panel and protrude from a top surface of the backer panel and are configured to mount the ceiling tile to a ceiling hanger system.
Claims
1. A ceiling system comprising: a backer panel comprising: a top surface; a bottom surface opposite the top surface; and a plurality of openings extending from the top surface to the bottom surface; a plurality of ceiling components, each of the plurality of ceiling components comprising: a main body; and a first end connector protruding upward from the main body and comprising a first end recess facing a first direction and configured to receive a flange portion of a first ceiling hanger; a second end connector protruding upward from the main body and comprising a second end recess facing a second direction opposite the first direction and configured to receive a flange portion of a second ceiling hanger; at least one ancillary connector protruding upward from the main body between the first and second end connectors, the least one ancillary connector comprising a first ancillary recess facing the first direction and a second ancillary recess facing the second direction, the first ancillary recess configured to receive a first portion of a flange portion of a third ceiling hanger and the second ancillary recess configured to receive a second portion of the flange portion of the third ceiling hanger; the plurality of ceiling components assembled to the backer panel to form a ceiling tile in which: (1) the main bodies of the plurality of ceiling components are below the backer panel; and (2) the first end connectors, the second end connectors, and the ancillary connectors of the plurality of ceiling components pass through the plurality of openings and protrude from the top surface of the backer panel.
2. The ceiling system according to claim 1 wherein each of the plurality of ceiling components comprises a plurality of the ancillary connectors arranged between the first and second end connectors in an equi-spaced manner from one another.
3. The ceiling system according to claim 2 wherein the spacing between plurality of the ancillary connectors is selected so that the plurality of the ancillary connectors align with route holes in a tee grid that allow for cross-tees to be mounted.
4. The ceiling system according to claim 1 wherein the backer panel and each of the plurality of ceiling components are formed of acoustic absorbing material.
5. The ceiling system according to claim 4 wherein the backer panel and each of the plurality of ceiling components are formed of felt.
6. The ceiling system according to claim 1 wherein the ceiling tile comprises the plurality of ceiling components assembled to the backer panel so that the main bodies of the plurality of ceiling components extend substantially parallel to one another.
7. The ceiling system according to claim 1 further comprising: for each the plurality of ceiling components, the main body comprising a panel; and the ceiling tile comprising the plurality of ceiling components assembled to the backer panel so that the panels of the main bodies of the plurality of ceiling components extend orthogonal from the bottom surface of the backer panel; and for each of the plurality of ceiling components, the panel of the main body, the first end connector, the second end connector, and the at least one ancillary connector is a monolithic component.
8. The ceiling system according to claim 1 wherein for each the plurality of ceiling components, the main body is formed by a folded piece of felt.
9. The ceiling system according to claim 1 wherein, for each of the plurality of ceiling components, the at least one ancillary connector further comprising: at least one pair of tabs comprising: a first tab comprising a first inner edge, the first ancillary recess formed in the first inner edge; and a second tab spaced from the first tab and comprising a second inner edge that opposes the first inner edge of the first tab to form a channel therebetween, the second ancillary recess formed in the second inner edge.
10. The ceiling system according to claim 9 wherein, for each of the plurality of ceiling components, the first and second ancillary recesses are horizontally aligned.
11. The ceiling system according to claim 9 wherein, for each of the plurality of ceiling components, the channel has an entry section above the first and second ancillary recesses that has a width that decreases with distance from an opening of the entry section.
12. The ceiling system according to claim 11 wherein, for each of the plurality of ceiling components, the entry section has a maximum width that is greater than a width of the flange portion of the third ceiling hanger and a minimum width that is less than the width of the flange portion of the third ceiling hanger.
13. The ceiling system according to claim 9 wherein for each of the plurality of ceiling components, the first inner edge of the first tab comprises a first chamfered portion and the second inner edge of the second tab comprises a second chamfered portion opposing the first chamfered portion.
14. The ceiling system according to claim 9 wherein, for each of the plurality of ceiling components, the at least one ancillary connector comprises two of the at least one pair of tabs, a first one of the pair of tabs aligned with the second one of the pair of tabs in a third direction that is orthogonal to the first and second directions.
15. The ceiling system according to any one of claims 9 further comprising: a ceiling hanger system comprising the first, second, and third ceiling hangers, each of the first, second, and third ceiling hangers being a tee grid beam; and the ceiling tile mounted to the ceiling hanger system due to a portion of a horizontal flange of the first ceiling hanger nesting within the first end recess, a portion of a horizontal flange of the second ceiling hanger nesting within the second end recess, and first and second end portions of a horizontal flange of the third ceiling hanger nesting within the first and second ancillary recesses respectively.
16. The ceiling system according to claim 1 wherein, for each of the plurality of ceiling components, the at least one ancillary connector further comprising: a tab comprising a first outer edge and a second outer edge opposite the first outer edge; and the first ancillary recess formed in the first inner edge and the second ancillary recess formed in the second outer edge.
17. The ceiling system according to claim 16 wherein, for each of the plurality of ceiling components, the at least one ancillary connector further comprising: the first outer edge comprising a first chamfered portion above the first ancillary recess; and the second outer edge comprising a second chamfered portion above the second ancillary recess.
18. The ceiling system according to any one of claim 16 further comprising: a ceiling hanger system comprising the first, second, and third ceiling hangers, the third ceiling hanger being a C-channel beam; and the ceiling tile mounted to the ceiling hanger system due to the flange portion of the first ceiling hanger nesting within the first end recess, the flange portion of the second ceiling hanger nesting within the second end recess, and first and second portions of the flange portion of the C-channel beam nesting within the first and second ancillary recesses respectively.
19. A ceiling system comprising: a backer panel comprising: a top surface; a bottom surface opposite the top surface; and a plurality of openings extending from the top surface to the bottom surface; a plurality of ceiling components, each of the plurality of ceiling components comprising: a main body; and a first end connector protruding upward from the main body and comprising a first end recess facing a first direction and configured to receive a flange portion of a first ceiling hanger; at least one ancillary connector protruding upward from the main body, the at least one ancillary connector comprising a first ancillary recess facing the first direction and a second ancillary recess facing the second direction, the first ancillary recess configured to receive a first portion of a flange portion of a second ceiling hanger and the second ancillary recess configured to receive a second portion of the flange portion of the second ceiling hanger; the plurality of ceiling components assembled to the backer panel to form a ceiling tile in which: (1) the main bodies of the plurality of ceiling components are below the backer panel; and (2) the first end connector and the ancillary connectors of the plurality of ceiling components pass through the plurality of openings and protrude from the top surface of the backer panel to allow mounting of the ceiling tile to a ceiling hanger system via the ancillary connectors engaging the second ceiling hanger and the first end connectors engaging the second ceiling hanger.
20. The ceiling system according to claim 19 further comprising: a ceiling hanger system comprising the first and second ceiling hangers; and the ceiling tile mounted to the ceiling hanger system due to the flange portion of the first ceiling hanger nesting within the first end recess and the first and second portions of the flange portion of the second ceiling hanger nesting within the first and second ancillary recesses respectively.
Description
DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a perspective view of a system including a wall system and a ceiling system in accordance with at least one embodiment of the present invention;
[0033] FIG. 2 is a perspective view of a rectilinear grid and a ceiling tile of the ceiling system of FIG. 1;
[0034] FIG. 3 is a perspective view of the ceiling tile of FIG. 2 attached to the rectilinear grid of FIG. 2;
[0035] FIG. 4 is a perspective view of a shortened version of the ceiling tile of FIG. 2 and a modified version of the rectilinear grid of FIG. 2;
[0036] FIG. 5 is an exploded view of a ceiling tile in accordance with at least one embodiment of the present invention;
[0037] FIG. 6 is a perspective view of a ceiling tile in accordance with at least one embodiment of the present invention;
[0038] FIG. 7 is another perspective view of the ceiling tile of FIG. 6;
[0039] FIG. 8 is a perspective view of an ancillary connector of the ceiling tile of FIG. 2, the ceiling tile of FIG. 4, the ceiling tile of FIG. 5, and the ceiling tile of FIG. 6;
[0040] FIG. 9 is an elevational view of the ancillary connector of FIG. 8;
[0041] FIG. 10A is a detail view of an ancillary connector of the ceiling tile of FIG. 6 being aligned with the rectilinear grid of FIG. 2;
[0042] FIG. 10B is a detail view of the ancillary connector of FIG. 10A attached to the rectilinear grid of FIG. 2;
[0043] FIG. 11 is an elevational view of end connectors of the ceiling tile of FIG. 6 attached to the rectilinear grid of FIG. 2;
[0044] FIG. 12 is a perspective view of the ceiling tile of FIG. 6 being attached to a modified version of the rectilinear grid of FIG. 2;
[0045] FIG. 13 is a perspective view of a ceiling tile in accordance with at least one embodiment of the present invention;
[0046] FIG. 14 is a perspective view of an ancillary connector of the ceiling tile of FIG. 13;
[0047] FIG. 15 is an elevational view of the ancillary connector of FIG. 14;
[0048] FIG. 16A is a detail view of an ancillary connector of the ceiling tile of FIG. 13 being aligned with a C-channel beam of a rectilinear grid;
[0049] FIG. 16B is a detail view of the ancillary connector of FIG. 16A attached to the C-channel beam of FIG. 16A;
[0050] FIG. 17 is an elevational view of end connectors of the ceiling tile of FIG. 13;
[0051] FIG. 18 is a detail view of a first end connector of the ceiling tile of FIG. 13 attached to the rectilinear grid of FIG. 16A;
[0052] FIG. 19 is a detail view of a second end connector of the ceiling tile of FIG. 13 attached to the rectilinear grid of FIG. 16A;
[0053] FIG. 20 is a perspective view of the ceiling tile of FIG. 13 and being attached to a modified version of the rectilinear grid of FIG. 16A;
[0054] FIG. 21 is an elevational view of a ceiling tile attached to a rectilinear grid in accordance with at least one embodiment of the present invention comprising both tee-beams and C-channel beams;
[0055] FIG. 22 is a perspective view of the ceiling tile of FIG. 21 and tee-beams and C-channel beams of the rectilinear grid of FIG. 21;
[0056] FIG. 23 is a plan view of a ceiling system in accordance with at least one embodiment incorporating the teachings herein;
[0057] FIG. 24 is a partial elevational view of a ceiling tile comprising at least one end connector attached thereto by at least one fastener; and
[0058] FIG. 25 is a perspective view of an ancillary connector that is attachable to a ceiling tile by at least one fastener.
[0059] The detailed description of the disclosure will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities of the examples shown in the drawings.
DETAILED DESCRIPTION
[0060] For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the art will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.
[0061] As used herein and in the appended claims, the singular forms a, an, and the include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical species. The terms a (or an), one or more and at least one may be used interchangeably herein. The terms comprising, including, containing, and having may be used interchangeably. The term include should be interpreted as include, but are not limited to. The term including should be interpreted as including, but are not limited to.
[0062] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. Thus, any range of values disclosed herein is merely exemplary and includes all values and sub-ranges there-between
[0063] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight of the total composition. Unless otherwise specified, reference to a molecule, or to molecules, being present at a wt. % refers to the amount of that molecule, or molecules, present in the composition based on the total dry-weight of the composition. Unless otherwise specified, reference to a molecule, or to molecules, being present based on the dry weight of the composition refers to that molecule, or molecules, being present in the composition based on the total dry-weight of the composition in a dry state. The dry state refers to solvent being present in the composition at an amount less than 5.0 wt. %, less than about 3.0 wt. %, less than about 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition. For example, a composition in the dry state may refer to a composition having about 95% solids, about 98% solids, preferably about 99% solids, or more preferably about 100% solids. By contrast, unless otherwise specified, reference to a molecule, or to molecules, being present based on the wet weight of the composition refers to that molecule, or molecules, being present in the composition based on the total dry-weight of the composition which includes at least 5 wt. % of solvent.
[0064] According to the present application, use of the term about in conjunction with a numeral value refers to a value that may be +/5% of that numeral. As used herein, the term substantially free is intended to mean an amount less than about 5.0 wt. %, less than 3.0 wt. %, less than 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition.
[0065] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, patent applications, publications, and other references cited or referred to herein are incorporated by reference in their entireties for all purposes. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure Comparatives.
[0066] In the description of examples 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 disclosure. Relative terms such as lower, upper, horizontal, vertical,, above, below, up, down, top and bottom as well as derivatives thereof (e.g., horizontally, downwardly, upwardly, etc.) should be construed to refer to the orientation as then described or as shown in the drawing (if applicable) under discussion. These relative terms are for convenience of description only and, unless specified otherwise, do not require that the apparatus be constructed or operated in a particular orientation.
[0067] As used herein, terms such as attached, affixed, connected, coupled, interconnected, and the like 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. Accordingly, the disclosure is not limited to such examples illustrating certain combinations of features that may exist alone or in combination with other features.
[0068] The present disclosure relates to acoustical ceiling baffles, tiles, and/or structures with ancillary connections that can be utilized when, for instance, a primary connection is unusable, inconveniently located, and/or has been removed. If a ceiling product needs to be installed where one or more primary connections to a building structure are hindered, the ancillary connections can be utilized to support the product. Such ancillary connections also allow for the staggered installation of the ceiling panels, as discussed below.
[0069] A surface covering system 1000 is illustrated in FIG. 1. The surface covering system 1000 comprises a ceiling system 2000 and a wall system 3000. The ceiling system 2000 comprises a ceiling hanger system 2100 and ceiling tiles 2200 attached to the ceiling hanger system 2100. The ceiling hanger system 2100 comprises a rectilinear grid including longitudinal and transverse beams extending orthogonally to one another; however, the ceiling hanger system 2100 can comprise any suitable configuration. In various embodiments, a grid can comprise curved beams, for example. In various embodiments, the longitudinal and transverse beams can extend relative to one another in non-orthogonal directions. The ceiling hanger system 2100 is mounted to a building structure using fasteners, rods, wires, and/or straps, for example. Referring to FIG. 2, the grid of the ceiling hanger system 2100 comprises longitudinal beams 2110 and transverse beams 2120 mounted to the longitudinal beams 2110. The longitudinal beams 2110 comprise pre-defined mounting locations at which the transverse beams 2120 can be mounted. Such mounting locations can comprise notches, or route holes, configured to at least partially receive the transverse beams 2120 at 6 intervals, for example. Such mounting locations can also comprise apertures configured to receive fasteners that secure the transverse beams 2120 to the longitudinal beams 2110. Various embodiments may not have such pre-defined mounting locations and/or apertures for the transverse beams 2120. In either case, the longitudinal beams 2110 and the transverse beams 2120 define grid openings 2115 therebetween. As illustrated in FIGS. 2 and 3, each ceiling tile 2200 extends across and/or covers two grid openings 2115; however, other embodiments are envisioned where a ceiling tile extends across and/or covers more than two grid openings and/or only one grid opening.
[0070] Further to the above, referring again to FIGS. 2 and 3, each ceiling tile 2200 comprises a backer panel 2210 and at least one ceiling component 2220 extending from the backer panel 2210. The backer panel 2210 comprises a first end 2211, a second end 2219 positioned opposite the first end 2211, a top surface 2215, and a bottom surface positioned opposite the top surface 2215. The backer panel 2210 can be comprised of any suitable material, such as felt, polyester felt, and/or PET felt, for example. In various embodiments, the backer panel 2210 can be comprised of any suitable material configured to absorb sound waves. The backer panel 2210 comprises longitudinal rows of openings, or slots, extending through the backer panel 2210 between the top surface 2215 and the bottom surface of the backer panel 2210. Each longitudinal row of openings includes a first opening 2212 at the first end 2211 of the backer panel 2210, a second opening 2213 at the second end 2219 of the backer panel 2210, and intermediate openings 2214 extending between the first opening 2212 and the second opening 2213. The intermediate openings 2214 are evenly spaced apart, or equi-spaced, between the first opening 2212 and the second opening 2213; however, other embodiments are envisioned in which at least some of the intermediate openings 2214 are not evenly spaced relative to one another. Moreover, the longitudinal rows of openings are parallel, or at least substantially parallel, to one another. In various instances, substantially parallel can mean sufficiently parallel so as to appear parallel to an observer. The openings in the backer panel 2210 are configured to receive tabs, or connectors, of the ceiling component 2220, as described in greater detail below.
[0071] Further to the above, referring again to FIGS. 2 and 3, each ceiling component 2220 comprises a main body 2221 and longitudinal rows of connectors extending from the main body 2221. The main body 2221 is comprised of a folded felt sheet but can be comprised of any suitable material. For instance, the main body 2221 can be comprised of polyester felt and/or PET felt, for example, and/or any suitable material configured to absorb sound waves. The folded sheet of felt is folded into a U-shaped configuration, for example, having a base and two upwardly-depending walls that extend from the base. To assist the felt sheet in being bent into its U-shaped configuration, the felt sheet can be scored or grooved along lines that define the joints between the base and the two upwardly-depending walls. Other embodiments, however, may not have such score marks or grooves. In either event, the base and the two upwardly-depending walls of the ceiling component 2220 define a longitudinal cavity in the ceiling tile 2200 when the ceiling component 2220 is assembled to the backer panel 2210. Such a longitudinal opening can assist in dissipating sound waves. In various embodiments, each ceiling component 2220 comprises a baffle.
[0072] Each longitudinal row of connectors comprises a first end connector 2222 at a first end of the main body 2221, a second end connector 2223 at a second end of the main body 2221, and intermediate, or ancillary, connectors 2224 positioned between the first end connector 2222 and the second end connector 2223. A longitudinal row of connectors is integrally-formed with each of the two upwardly-depending walls of the main body 2221; however, further to the below, embodiments are envisioned in which the connectors 2222, 2223, and/or 2224 are assembled to the upwardly-depending walls. In either case, each ceiling component 2220 comprises two longitudinal rows of connectorsone on each upwardly-depending wall of the main body 2221.
[0073] Further to the above, referring again to FIGS. 2 and 3, the ceiling components 2220 of the ceiling tile 2200 can be assembled to the backer panel 2210 in any suitable manner. In at least one instance, a ceiling component 2220 is assembled to the backer panel 2210 such that all of the connectors of the ceiling component 2220 are inserted through their respective openings in the backer panel 2210 simultaneously. In various embodiments, the openings are sized and configured such that there is clearance between the connectors of the ceiling component 2220 and the openings of the backer panel 2210 such that there is little, if any, interference between the connectors and the sidewalls of the openings. In other embodiments, the first end connectors 2222, for example, may be sized and configured to contact the sidewalls of the first openings 2212 such that the first end connectors 2222 resiliently deform when passing through the first openings 2212 and then resiliently return back to their undeformed shape after passing through the first openings 2212. Similarly, the second end connectors 2223, for example, may be sized and configured to contact the sidewalls of the second openings 2213 such that the second end connectors 2223 resiliently deform when passing through the second openings 2213 and then resiliently return back to their undeformed shape after passing through the second openings 2213. Also, similarly, the ancillary connectors 2224, for example, may be sized and configured to contact the sidewalls of the intermediate openings 2214 such that the ancillary connectors 2224 resiliently deform when passing through the intermediate openings 2214 and then resiliently return back to their undeformed shape after passing through the intermediate openings 2214. In various other instances, a ceiling component 2220 is rocked into position when the ceiling component 2220 is assembled to the backer panel 2210. In at least one such instance, the first end connectors 2222 are fed, or inserted, through the first openings 2212 and then the ceiling component 2220 is rotated into position until the second end connectors 2223 are inserted through the second openings 2213. In some such instances, the second end connectors 2223 may need to be snap-fit through their respective second openings 2213 to fully assemble the ceiling components 2220 to the backer panel 2210.
[0074] After the ceiling components 2220 have been assembled to the backer panel 2210, the ceiling panel 2200 can be attached to the ceiling hanger system 2100. Typically, the ceiling tiles 2200 are attached to the ceiling hanger system 2100 after the ceiling hanger system 2100 has been attached to a building structure, but that is not required. In either case, as discussed in greater detail below, a recess is defined between each of the connectors and the top surface 2215 of the backer panel 2210 that is configured to receive a portion of a transverse beam 2120 therein. Owing to the engagement between the connectors of the ceiling panel 2200 and the transverse beams 2120 of the ceiling hanger system 2100, the ceiling components 2220 hang from the transverse beams 2120. As such, the transverse beams 2120 can be referred to as ceiling hangers. The delineation of the terms first, second, or third ceiling hanger is used for exemplary description only. Any one of the terms first, second, or third may be used to describe the ceiling hangers depending upon the context and order in which it is used in the claims. For example, in claim 1, the term ceiling hanger is used in context with a first end connector protruding upward from the main body and comprising a first end recess facing a first direction and configured to receive a flange portion of a first ceiling hanger and at least one ancillary connector protruding upward from the main body between the first and second end connectors . . . the first ancillary recess configured to receive a first portion of a flange portion of a second ceiling hanger.
[0075] Referring primarily to FIGS. 10A, 10B, and 11, each transverse beam 2120 has a T-shaped cross-section including a flange portion 2130 and a central beam portion 2140. The flange portion 2130 comprises two laterally-extending flanges extending from the opposite sides of the central beam portion 2140 that, as discussed in greater detail below, are sized and configured to be received in the recesses defined by the connectors of the ceiling panel 2200. In various instances, as a result of the above, the transverse beams 2120 can be referred to as tee-beams, tee grid beams, cross-tees, or the like, for example.
[0076] Further to the above, referring to FIG. 11, each first end connector 2222 comprises a chamfer 2228a and a recess 2229a. When the ceiling panel 2200 is assembled to the ceiling hanger system 2100, the chamfer 2228a can come into contact with the flange portion 2130 of a first transverse beam 2120. Similarly, each end connector 2223 comprises a chamfer 2228b and a recess 2229b where the chamfer 2228b can also come into contact with a second transverse beam 2120. The chamfers 2228a and 2228b of the first end connectors 2222 and the second end connectors 2223, respectively, are configured to co-operatively guide and position the ceiling panel 2200 relative to the ceiling hanger system 2100 such that the ceiling panel 2200 is sufficiently aligned with the ceiling hanger system 2100, i.e., such that the flange portions 2130 of the first transverse beams 2120 enter into the first recesses 2229a of the first end connectors 2222 and the flange portions 2130 of the second transverse beams 2120 enter into the second recesses 2229b of the second end connectors 2223. Notably, the first recesses 2229a of the first end connectors 2222 and the second recesses 2229b face in opposite directions. Stated another way, the first recesses 2229a of the first end connectors 2222 face, or open to, a first direction and the second recesses 2229b of the second end connectors 2223 face, or open to, a second direction that is opposite the first direction. In various instances, the engagement between the first and second end connectors 2222, 2223 and the first and second transverse beams 2120, respectively, is sufficient to retain the ceiling tile 2200 to the ceiling hanger system 2100. However, as discussed below, the ancillary connectors 2224 of the ceiling tile 2200 can, in addition to or in lieu of the above, retain the ceiling tile 2200 to the ceiling hanger system 2100.
[0077] Further to the above, referring to FIGS. 8, 9, 10A and 10B, each ancillary connector 2224 comprises a first tab 2224a and a second tab 2224b. The first tab 2224a comprises a first inner edge including a chamfered portion 2228a and a recess 2229 defined therein. Similarly, the second tab 2224b comprises a second inner edge including a chamfered portion 2228b and a recess 2229 defined therein. The first tab 2224a and the second tab 2224b are positioned and arranged such that their inner edges face, or oppose, one another and define a channel 2230 therebetween. As a result, the chamfered portions 2228a and 2228b oppose one another. Moreover, the recesses 2229 are horizontally, or laterally, aligned and oppose one another. Owing to the configuration of the chamfered portions 2228a and 2228b, the channel 2230 comprises a tapered configuration. The channel 2230 comprises a width at an open end that narrows between the chamfered portions 2228a and 2228b and then widens as a result of the recesses 2229. The width at the open end of the channel 2230 is wider than the flange portion 2130 of the transverse beam 2120. When the ceiling panel 2200 is assembled to the ceiling hanger system 2100, referring to FIGS. 10A and 10B, the wider opening of the channel 2230 facilitates the insertion of a transverse beam 2120 into the channel 2230 of the ancillary connector 2224. The channel 2230 narrows such that the flange portion 2130 of the transverse beam 2120 is wider than the narrowest part of the channel 2230. As a result, the flange portion 2130 comes into contact with the chamfered portions 2228a and 2228b when the ancillary connector 2224 is attached to the transverse beam 2120 which causes the tabs 2224a and 2224b to flex laterally outwardly. In order to fully seat the ancillary connector 2224 on the transverse beam 2120, the ceiling panel 2200 is pushed upwardly until the chamfered portions 2228a and 2228b disengage from the flange portion 2130 and the recesses 2229 are laterally aligned with the flange portion 2130. At such point, the tabs 2224a and 2224b resiliently return toward their unflexed state and the ancillary connector 2224 is locked to the transverse beam 2120. Notably, the channels 2229 define a width therebetween that is slightly larger than or equal to the width of the flange portion 2130. As a result, the ancillary connector 2224, either individually and/or collectively with other ancillary connectors 2224, can prevent, or at least inhibit, relative movement between the ceiling panel 2200 and the ceiling hanger system 2100.
[0078] Referring again to FIGS. 2 and 3, the first end connectors 2222 of the ceiling panel 2220 are connected to a first transverse beam 2120, the second end connectors 2223 are connected to a second transverse beam 2120, and a transverse row of ancillary connectors 2224 are connected to a third transverse beam 2120 positioned intermediate the first and second transverse beams 2120. Notably, the third transverse beam 2120 in FIGS. 2 and 3 is evenly spaced, or equi-spaced, between the first transverse beam 2120 and the second transverse beam 2120. That said, further to the above, the transverse beams 2120 can be connected to the longitudinal beams 2110 at more than one location to accommodate the dimensions of a space and/or obstructions created by the building structure, for example. In such instances, one or more of the transverse beams 2120 may not be equally spaced relative to the other transverse beams 2120. For example, referring to FIG. 4, the first transverse beam 2120 has been moved toward the third transverse beam 2120. In such instances, a first end 2121 of the first transverse beam 2120 is detached from a first longitudinal beam 2110 and a second end 2122 of the first transverse beam 2120 is detached from a second longitudinal beam 2110 such that the first transverse beam 2120 can be re-attached to the first and second longitudinal beams 2110 at another location, such as at predefined route holes defined in the first and second longitudinal beams 2110. In various embodiments, the route holes are spaced and arranged at equi-distant locations along the first and second longitudinal beams 2100. In such embodiments, the transverse rows of the ancillary connectors 2224 of the ceiling tile 2200 are also spaced and arranged such that the transverse rows of the ancillary connectors 2224 are aligned with the route holes defined in the first and second longitudinal beams 2110. Moreover, the first end connectors 2222 and the second end connectors 2223 are spaced and arranged such that transverse rows of the first end connectors 2222 and the second end connectors 2223 are aligned with the route holes defined in the first and second longitudinal beams 2110. In such instances, as a result, the transverse beams 2120 are always aligned with a transverse row of connectors of the ceiling panel 2200 regardless of their position so long as the transverse beams 2120 are mounted to the first and second longitudinal beams 2110 at the predetermined locations.
[0079] Further to the above, the ceiling panel 2200 can be trimmed to accommodate the dimensions of a space and/or obstructions created by the building structure, for example. Referring again to FIG. 4, the backer panel 2210 and the ceiling components 2220 of the ceiling panel 2200 have been transected along a transverse axis, such as by a saw, for example, to create a modified ceiling panel 2200 comprising a truncated backer panel 2210 and truncated ceiling components 2220'. As a result of the above, as can be seen in FIG. 4, the ceiling panel 2200 no longer has the first end connectors 2222. Such changes notwithstanding, the ceiling panel 2200 has a sufficient arrangement of ancillary connectors 2224 that can allow the ceiling panel 2200 to be attached to three or more transverse beams 2120, for example. In this embodiment, the modified ceiling panel 2220 extends across a grid opening 2115 and a modified grid opening 2115 that is smaller than the grid opening 2115. Moreover, the first end 2211 of the backer panel 2210 is still directly supported by the first transverse beam 2120, as well as the second 2219 of the backer panel 2210 is still directly supported by the second transverse beam 2120. That said, embodiments are envisioned in which one or both of the first and second ends 2211, 2219 of the backer panel 2210 are not directly supported by a transverse beam 2210 positioned thereunder. In such embodiments, one or both of the first and second ends 2211, 2219 of the backer panel 2210 comprise cantilevers that are not directly supported by a transverse beam 2210 positioned thereunder. Such arrangements can be useful for adapting the ceiling system 2000 to accommodate the dimensions of a room and/or obstructions created by the building structure, for example.
[0080] Further to the above, the rectilinear grid of the ceiling hanger system 2100 can support the ceiling tiles 2200 in an array which covers the ceiling of a room or space defined in a building. Absent more, the ceiling tiles 2200 can be positioned and arranged such that the ends 2211 and 2219 of the backer panels 2210 are aligned according to a regular, repeating pattern. Such a regular, repeating pattern, however, may be undesirable in some circumstances as an observer may not consider such a pattern to be very aesthetic. Referring to FIG. 23, a ceiling system 2000 comprises a ceiling hanger system 2100 and ceiling tiles 2200 mounted to the ceiling hanger system 2100 where the ceiling tiles 2200 are not positioned in a repeating pattern, or at least not a readily noticeable one. As can be seen in FIG. 23, the ends 2211 and 2219 of the backer panels 2210 are shifted longitudinally such that the ends 2211 and 2219 are at various positions relative to one another. The connection systems disclosed herein allow this to occur. The ancillary connectors 2224, for example, permit the ceiling tiles 2200 to be positioned in a multitude of positions that are not squarely aligned with the grid openings 2215 defined in the ceiling hanger system 2100. Such positions, absent more, can create overhangs 2001 and openings 2009 in the ceiling system 2000'; however, as discussed above, the connection systems disclosed herein permit the ceiling tiles 2200 to be truncated to eliminate the overhangs 2001 and/or allow shorter ceiling tiles 2200 to be used to fill the openings 2009.
[0081] Further to the above, a ceiling tile 5200 is illustrated in FIGS. 6, 7, and 12. The ceiling tile 5200 is similar to the ceiling tile 2200, and the other ceiling tiles disclosed herein, in many respects. The ceiling tile 5200 comprises a backer panel 5210 which is similar to the backer panel 2210, and ceiling components 5220 assembled to the backer panel 5210. The backer panel 5210 comprises a top surface 5215, a bottom surface 5216, and longitudinal rows of openings extending there through that are configured to receive longitudinal rows of connectors extending from the ceiling components 5220. The ceiling components 5220 are wider than the ceiling components 2220 but can comprise any suitable configuration. Similar to the ceiling components 2220, each ceiling component 5220 has two longitudinal rows of connectors 2222, 2223, and 2224 extending through the openings defined in the backer panel 2210. Moreover, further to the above, the ceiling tile 5200 is illustrated as being attached to four transverse beams 2120 that are spaced apart in an irregular manner.
[0082] Further to the above, the ceiling components 2220 of the ceiling tile 2200 extend parallel, or at least substantially parallel, to one another. In various instances, substantially parallel can mean sufficiently parallel so as to appear parallel to an observer. Moreover, the width of the ceiling components 2220 is uniform, or substantially uniform, along the length thereof such that the ceiling tile presents a symmetrical aesthetic appearance. Moreover, a gap is present between adjacent ceiling components 2220. Such gaps can be uniform, or at least substantially uniform, such that the ceiling tile 2200 presents a symmetrical aesthetic appearance. In various instances, substantially uniform can mean sufficiently uniform so as to appear uniform to an observer. Similarly, the ceiling components 5220 of the ceiling tile 5200 extend parallel, or at least substantially parallel, to one another. Moreover, the width of the ceiling components 5220 is uniform, or substantially uniform, along the length thereof such that the ceiling tile presents a symmetrical aesthetic appearance. Moreover, a gap is present between adjacent ceiling components 5220. Such gaps can be uniform, or at least substantially uniform, such that the ceiling tile 5200 presents a symmetrical aesthetic appearance.
[0083] Further to the above, a ceiling tile 7200 is illustrated in FIG. 5. The ceiling tile 7200 is similar to the ceiling tiles 2200 and 5200, and the other ceiling tiles disclosed herein, in many respects. The ceiling tile 7200 comprises a backer panel 7210 and ceiling components 7220 and 7220 attached to the backer panel 7210. Similar to the backer panel 2210, the backer panel 7210 comprises longitudinal rows of openings, each row including a first opening 2212, a second opening 2213, and intermediate openings 2214 defined therebetween. Similar to the ceiling component 2220, the ceiling component 7220 comprises a main body 7221 comprising a U-shaped configuration. The main body 7221 is formed from a folded sheet of felt, for example, and comprises a base 7226 and two upwardly-depending walls 7225 extending from the base 7226. Each of the upwardly-depending walls 7225 comprises a longitudinal row of integrally-formed, or monolithically-formed, connectors, each row including a first connector 2222, a second connector 2223, and ancillary connectors 2224 extending therebetween that are received in, and extend through, the first opening 2212, the second opening 2213, and the intermediate openings 2214, respectively. Further to the below, embodiments are envisioned in which the first connectors 2222, the second connectors 2223, and/or the ancillary connectors 2224 are fastened to and/or otherwise assembled to the ceiling component 7220. After the ceiling component 7220 has been assembled to the backer panel 7210, the walls 7225 of the ceiling component 7220 extend downwardly away from the backer panel 7210. In various embodiments, the walls 7225 extend orthogonally from a bottom surface of the backer panel 7210, for example, and the base 7226 extends orthogonally between the walls 7225 to form a rectangular longitudinal cavity 7227 between the ceiling component 7220 and the backer panel 7210. The ceiling tile 7200 further comprises a ceiling component 7220 that also forms a rectangular longitudinal cavity. That said, the walls of the backer panel 7210 can comprise any suitable configuration. For instance, the ceiling tile 7200 further comprises a ceiling component 7220 that forms a square longitudinal cavity.
[0084] Further to the above, referring again to FIGS. 10A, 10B, and 11, the transverse beams 2120 of the ceiling hanger system 2100 have a T-shaped cross-section. That said, the transverse beams 2120 can comprise any suitable cross-section. Referring to FIGS. 13-19, a ceiling tile 4200 is configured to be used with a ceiling hanger system comprising transverse beams having a C-shaped cross-section. The ceiling tile 4200 comprises a backer panel 4210 and a plurality of ceiling components 4220 assembled to the backer panel 4210. The backer panel 4210 comprises a first end 4211, a second end 4219 opposite the first end 4211, and longitudinal rows of openings, or through holes, defined therein extending between the first end 4211 and the second end 4219. The ceiling components 4220 comprise longitudinal rows of connectors extending from a main body 4221 thereof that are received within and extend through the openings defined in the backer panel 4210. The connectors extend or protrude upwardly from a top surface 4215 of the backer plate 4210 and the main body 4221 extends downwardly below a bottom surface of the backer plate 4210. Each longitudinal row of connectors comprises a first end connector 4222 at the second end 4219 of the backer plate 4210, a second end connector 4223 at the first end 4211 of the backer plate 4210, and ancillary connectors 4224 extending between the first end connector 4222 and the second end connector 4223, as discussed further below.
[0085] Further to the above, a transverse beam 4120 comprising a C-shaped cross-section is illustrated in FIGS. 18 and 19. The transverse beam 4120 comprises a back span 4140 and downwardly-depending walls 4137 extending from the back span 4140. Each wall 4137 comprises an end flange 4138 defined thereon that culminates in an end hook 4139. Referring to FIGS. 17 and 18, the first end connector 4222 comprises an inwardly-facing edge including a chamfered portion 4228a and a recess 4229. When the ceiling panel 4200 is assembled to the ceiling hanger system, referring to FIG. 18, the chamfered portion 4228a of the first end connector 4222 engages an end flange 4138 of a transverse beam 4120 such that the first end connector 4222 flexes outwardly. In such a flexed state, the first end connector 4222 can pass through an opening 4130 defined between the end flanges 4138 of the transverse beam 4120. As the ceiling panel 4200 is fully seated on the ceiling hanger system, the chamfered portion 4228a of the first end connector 4222 disengages from the end flange 4138 and resiliently returns toward its unflexed state such that the first end connector 4222 moves behind the end hook 4139 associated therewith. Moreover, in such instances, the end flange 4138 enters into the recess 4229 defined by the first end connector 4222 and, as a result, the first end connector 4222 becomes locked to the transverse beam 4120.
[0086] Similarly, referring to FIGS. 17 and 19, the second end connector 4223 comprises an inwardly-facing edge including a chamfered portion 4228b and a recess 4229. When the ceiling panel 4200 is assembled to the ceiling hanger system, referring to FIG. 19, the chamfered portion 4228b of the second end connector 4223 engages an end flange 4138 of a transverse beam 4120 such that the second end connector 4223 flexes outwardly. In such a flexed state, the second end connector 4223 can pass through the opening 4130 defined between the end flanges 4138 of the transverse beam 4120. As the ceiling panel 4200 is fully seated on the ceiling hanger system, the chamfered portion 4228b of the second end connector 4223 disengages from the end flange 4138 and resiliently returns toward its unflexed state such that the second end connector 4223 moves behind the end hook 4139 associated therewith. Moreover, in such instances, the end flange 4138 enters into the recess 4229 defined by the second end connector 4223 and, as a result, the second end connector 4223 becomes locked to the transverse beam 4120. Notably, the recess 4229 of the first end connector 4222 faces a first direction and the recess 4229 of the second end connector 4223 faces a second direction that is opposite the first direction. As a result of this arrangement, the first end connector 4222 and the second end connector 4223 can co-operatively hold the ceiling tile 4200 to the ceiling hanger system such that there is little, if any, relative movement between the ceiling tile 4200 and the ceiling hanger system.
[0087] Referring to FIGS. 14, 15, 16A, and 16B, each ancillary connector 4224 comprises a first tab 4224a and a second tab 4224b that are connected to one another and at least partially separated from one another by a notch 4227. The first tab 4224a comprises an outwardly-facing surface comprising a chamfered portion 4228a and a recess 4229 that faces in the first direction. Similarly, the second tab 4224b comprises an outwardly-facing surface comprising a chamfered portion 4228b and a recess 4229 that faces in the second direction. When the ceiling panel 4220 is assembled to the ceiling hanger system, further to the above, the end flanges 4138 of a transverse beam 4120 can contact the chamfered portions 4228a and 4228b of the first and second tabs 4224a and 4224b, respectively, and flex the tabs 4224a and 4224b inwardly toward one another. The notch 4227, mentioned above, is configured to allow the tabs 4224a and 4224b to resiliently deflect toward one another and, after passing through the opening 4130 defined in the transverse beam 4120, the tabs 4224a and 4224b can return toward their unflexed state after disengaging from the end flanges 4138. In such instances, the tabs 4224a and 4224b can move behind their respective end hooks 4139 and the end flanges 4138 can enter into the recesses 4229 defined by the first and second tabs 4224a and 4224b to lock the ancillary connector 4224 to the transverse beam 4120. In addition to or in lieu of the benefits provided by the first and second end connectors 4222 and 4223, the ancillary connectors 4224 can hold the ceiling tile 4200 to the ceiling hanger system such that there is little, if any, relative movement between the ceiling tile 4200 and the ceiling hanger system.
[0088] As discussed above, the transverse beam 4120 comprises a C-shaped cross-section. As a result, the transverse beam can be referred to as a C-channel beam, for example. In various embodiments, embodiments are envisioned in which all of the transverse beams of a ceiling hanger system have a T-shaped cross-section, such as transverse beams 2120, for example, or, alternatively, embodiments are envisioned in which all of the transverse beams of a ceiling hanger system have a C-shaped cross-section, such as transverse beams 4120. Yet other embodiments are envisioned that have both transverse beams 2120 and transverse beams 4120, for example. Referring to FIGS. 21 and 22, a ceiling tile 8200 is configured to be attached to transverse beams 2120 and 4120. The ceiling tile 8200 comprises a backer panel 8210, ceiling components 8220 attached to the backer panel 8210, and a sufficient arrangement of connectors, such as those disclosed herein, that permit the ceiling tile 8200 to be attached to at least one transverse beam 2120 and at least one transverse beam 4120.
[0089] Further to the above, a ceiling tile 6200 is illustrated in FIG. 24 that is similar to the ceiling tiles 2200, 4200, 5200, 7200, and 8200, and the other ceiling tiles disclosed herein, in many respects. The ceiling tile 6200 comprises a backer panel 6210 and one or more ceiling components 6220 assembled to the backer panel 6210. The ceiling tile 6200 further comprises a first end connector 6222 attached to a ceiling component 6220 by a fastener, such as a screw, for example. The first end connector 6222 comprises a block of material including an opening 6227 extending there through that is configured to receive the fastener therein. In various embodiments, the first end connector 6222 can have more than one opening 6227 and/or can be attached to the ceiling component 6220 by more than one fastener. The first end connector 6222 is similar to the first end connector 2222 in many respects. For instance, the first end connector 6222 comprises a bevel portion 2228a and also defines a laterally-facing recess 2229a, as described above. The ceiling tile 6200 also comprises second end connectors that are attached to the ceiling components 6220 in a similar manner but define recesses that face in the opposite direction to those of the first end connectors 6222. Referring to FIG. 25, the ceiling tile 6200 further comprises ancillary connectors 6224 that are attached to the ceiling components 6220. Each ancillary connector 6224 comprises a body, or block, 6225 including an opening 6226 extending there through that is configured to receive a fastener therein. In various embodiments, the ancillary connectors 6224 can have more than one opening 6226 and/or can be attached to the ceiling component 6220 by more than one fastener. The ancillary connector 6224 is similar to the ancillary connector 2224 in many respects. For instance, the ancillary connector 6224 comprises a first tab 2224a and a second tab 2224b which define a channel 2230 therebetween that is configured to receive a flange portion 2130 of a transverse beam 2120, as described above.
[0090] In various embodiments, further to the above, a ceiling tile can have connectors that are integrally-formed, or monolithically formed, with a ceiling component as well as connectors that are assembled to a ceiling component. For instance, one ceiling component can have integrally-formed connectors while another ceiling component can have assembled connectors. In at least one embodiment, a ceiling component can have both integrally-formed connectors and assembled connectors. In various embodiments, a ceiling component may not have connectors at all. Instead, such ceiling components can be attached to, or formed monolithically with, a backer panel that has connectors sufficient to hang a ceiling panel to the ceiling hanger system 2100, for example. In various embodiments, the backer panel comprises connectors that are integrally formed, or monolithically formed, therewith and/or connectors assembled, or fastened, thereto. In various embodiments, a connector that is assembled to a ceiling component and/or backer panel can be comprised of a plastic block and/or a metal clip, for example.
[0091] Although the above-provided examples were discussed in connection with ceiling systems, such examples can be adapted to wall systems, such as wall system 3000 in FIG. 1, for example.
[0092] While the present disclosure has been described with reference to several examples, which examples have been set forth in considerable detail for the purposes of making a complete disclosure of the disclosure, such examples are merely representative and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the disclosure. The scope of the disclosure is to be determined from the claims appended hereto. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the disclosure.
