SUSPENDED CEILING

Abstract

A drop ceiling frame construction is provided having a circular support frame and a plurality of T-shaped frame members radially disposed from the circular support frame. At least partially disposed through the circular support frame are components selected from the group including of a light, a sensor, sprinkler head, a smoke detector, and a camera.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/142,003, filed on Apr. 2, 2015. The entire disclosure of the above application is incorporated herein by reference.

FIELD

The present disclosure relates to drop ceiling construction and, more specifically, to a roll formed members for a drop-ceiling frame.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art. Traditionally, a drop ceiling is constructed from a metal frame in the form of a matrix of circular support member 10s which are generally of extruded or roll formed metal. The frame is used to support acoustic tile panels and light fixtures. Drop ceiling construction has become popular in office building design as they provide an architecturally pleasing appearance and provides a space between the drop ceiling and the structural ceiling for heating and air conditioning ducts, plumbing, and wiring. Unfortunately, access to the space between the drop ceiling and the structural ceiling through the ceiling tile is labor intensive and can damage fire safety features.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. The present invention is directed to a drop ceiling frame construction which can be roll formed of sheet metal have predefined curved or circular frame members. These predefined curved or circular frame members can be coupled between adjacent straight frame members. The curved and straight members are supported to the ceiling structure using support rods or wires. A slot arrangement provides a mechanism of attaching predefined curved or circular frame members to the frame at any point along the length of a circular support member forming the frame.

The predefined curved or circular frame members are formed by rolling sheet material to form a circular web having a predetermined radius. Coupling slots or apertures that allow the coupling of the circular flanges to linear members are formed in the web prior to or after shaping the web. A circular support surface is coupled to the when using ben flanges, adhesive, or flanges. The slots extend in a direction transverse to the radial axis of the predefined curved or circular frame members. Linear members radiate from the circular frame and are combined to form a grid pattern.

A drop ceiling frame construction is provided having a circular support frame and a plurality of T-shaped frame members radially disposed from the circular support frame. A ceiling tile defining a straight edge engaged with one of plurality of T-shaped frame members and a curved edge coupled to the circular support frame. At least partially disposed through the circular support frame is a component selected from the group including a light, a sensor, sprinkler head, a smoke detector, and a camera. The component can be fixably coupled to the circular support frame.

According to the present teachings, a drop ceiling frame construction can have a first T-shaped suspended frame member and a second T-shaped suspended frame member coupled to the first T-shaped frame member at a 90 degree angle. An T- or L-shaped cross section curved support frame is coupled to both the first and second T-shaped suspended frame members. A ceiling tile defining a first straight edge engaged with the first T-shaped frame members and a curved surface coupled to the curved support frame. The ceiling tile defines a second straight edge engaged with the second T-shaped support frame.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

For a better understanding of the invention, reference should be made to the accompanying drawings, wherein:

FIG. 1 is an isometric view of a predefined curved or circular frame members coupled to the matrix of T-frame members;

FIG. 2 is a bottom view showing the detail at an intersection between a predefined curved or circular frame members and a pair of cross members;

FIGS. 3A and 3B are sectional views taken substantially on the line 3-3 of FIG. 2;

FIG. 4 is a sectional view taken substantially on the line 4-4 of FIG. 2;

FIG. 5 represents an alternate embodiment of the present teachings; and

FIG. 6 represents a section of the embodiment shown in FIG. 6.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings. FIG. 1 is an isometric view of a predefined curved or circular frame member 10 coupled to the matrix of linear T-shaped frame members 12 to form the frame of a drop ceiling 14. The predefined curved or circular frame member 10 is roll formed to a predetermined radius from a single layer of metal sheet or folded a longitudinal strip of sheet metal material, such as aluminum or steel. The members can be roll formed into any desired length by conventional roll forming techniques.

The curved 10 and linear T-shaped frame members 12 members are supported to the ceiling structure using support rods or wires 18. A slot arrangement provides a mechanism of attaching predefined curved or circular frame members 10 to the linear T-shaped frame members 12 at any point along the length of a linear T-shaped frame member 12 forming the frame. Alternatively, the circular frame members 10 can be located as a central support location at the intersection of two, three, or four linear T-shaped frame members 12.

The sheet metal is formed to provide a web section 20 of the circular frame members 10 consisting of two layers of the sheet metal normally lying in intimate contact. The upper edge 22 of the web section 20 can be formed into a deformed channel or box frame section 24 that strengthens the upper edge 22 of the web section against lateral bending. Folding the sheet metal to bring the sheet metal back together to form the two layers of the web sections can form the section 24.

At the lower edge of the web section 26, the sheet metal layers can be bent outwardly and then downwardly to form a perpendicular ceiling support section. Alternatively, a circular support surface is coupled to the when using ben flanges, adhesive, or flanges.

FIGS. 2-4, show a bottom view showing the detail at an intersection between a predefined curved or circular frame members and a pair of cross members shown in FIG. 1. The intersection is formed by two linear T-shaped frame members 12, which are in axial alignment with each other and extend perpendicular to the circular support member 10. As best seen in FIG. 4, the ends of the abutting cross members 12 and 12′ are shaped to fit the cross-sectional contour of the circular support member 10. Once coupled to the web portion, the circular support member can have a generally L-shaped or T-shaped cross section. At the web portion of the circular support member 10, a vertical slot receives extensions or tongues that project from the ends of the respective T-shaped frame members 12. The tongues hold the T-shaped frame members 12 in alignment and at the same time lock the cross members to the circular support member 10.

As best seen in FIG. 2, the support sections, for the circular support member 10, and T-shaped linear frame members 12, are held in abutting relationship with the edge of the circular flange sections of the circular support member 10. Thus the circular support member 10 interrupts and supports the end of the T-shaped frame members 12. In addition to being supported at the ends, the T-shaped frame members 12 and circular support member 10 are coupled to the ceiling using drop rods or drop wires.

Normally square or rectangular ceiling tiles 32 can have a quarter or half circular cut out defined therein to allow proper mating with the circular frame 10. The tiles are supported at their periphery by the support flange of the circular support member 10 and the T-shaped frame members 12.

As best shown in FIGS. 3 and 4, the slots can be pre-formed in the sheet metal strip before it is roll formed into the desired structural shape. The slots extend from the folded outer margin of the flange sections to the inner deformed or box support section. The inner layers of the web sections can then be dimpled or crimped along the length of the slots, to provide additional depth to the slots for the coupling members of the T-shaped frame members 12 or the suspension rods or wires.

By forming the slots prior to the formation of the radius of curvature, the structural integrity of the circular support member 10 is maintained. At the same time, by removing the outer layer of the sheet metal in the slots, the surface of the inner layer of the flange sections is exposed.

Decorative covers 38 can be placed within the circular frame 10. These decorative covers 38 can be selectively removable from the circular frame 10. The covers 30 can have engagement surfaces that selectively engage with surfaces within the circular frame 10.

FIG. 5 represents an alternate embodiment of the present teachings where T-shaped frame members 12 are coupled together to form a grid. Disposed between a pair of perpendicularly engaging T-shaped frame members 12 is curved frame 10. In this embodiment, the curved frame represents about 90 degrees of a complete circle. Four 90 degree curved members can be used to form a circular access point. Complementary to this structure are four ceiling tiles having semi-circular cutouts.

FIG. 6 represents a section of the embodiment shown in FIG. 5. The sectional view shows the coupling mechanism alternate embodiment of the present teachings where T-shaped frame members 12 are coupled together to form a grid. Disposed between a pair of perpendicularly engaging T-shaped frame members 12 is curved frame 10. In this embodiment, the curved frame represents about 90 degrees of a complete circle. Four 90 degree curved members can be used to form a circular access point. Complementary to this structure are four ceiling tiles having semi-circular cutouts.

As shown in FIGS. 5 and 6, the drop ceiling frame construction can have a first T-shaped suspended frame member and a second T-shaped suspended frame member coupled to the first T-shaped frame member at a 90 degree angle. A T- or L-shaped cross section curved support frame is coupled to both the first and second T-shaped suspended frame members. A ceiling tile defining a first straight edge engaged with the first T-shaped frame members and a curved surface coupled to the curved support frame. The ceiling tile defines a second straight edge engaged with the second T-shaped support frame.

As shown in FIG. 5, the curved support frame has a first coupling flange defined at a first end configured to engage the first T-shaped suspended frame member, and a second coupling flange configured to engage the second T-shaped suspension frame member. The first and second T-shaped support frame members define coupling slots, where the first coupling flange is disposed within the coupling slot. At a second end of the curved support frame, the second T-shaped support frame has support surface where the second coupling flange engages the support surface.

Additionally, to prevent rotation of the curved flange, a surface bears against a side surface of the ceiling tile support flange. The curved support frame member can represent a full or partial circle which can be defined around the intersection of T-shaped members, or can be a centralized circular (See for example FIGS. 1 and 4.) having a radially disposed curved tile support flange and a body member defining a plurality of coupling slots. The T-shaped members have can be divided into a first plurality of T-shaped frame members and a second plurality of T-shaped frame members each having a coupling flange coupled to one of the plurality of coupling slots, wherein said first and second plurality of T-shaped frame members defining a grid pattern.

The curved support frame members are a circular member having a radially disposed support tile support flange. The System can have a ceiling tile having a first straight edge coupled to one of the second T-shaped frame members, and the ceiling tile can defining a second curved surface engaged to the radially disposed curved tile support flange, and a component at least partially disposed through the circular support frame the component selected from the group consisting of a light, a sensor, sprinkler head, a smoke detector, a camera.

This intersection construction provides the effect of continuous intersecting supports while forming a rigid ceiling grid structure having access to the space above the ceiling tiles. The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the Figure s. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the Figure s. For example, if the device in the Figure s is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Claims

1. A drop ceiling frame construction comprising:

a circular support frame;

a plurality of T-shaped frame members radially disposed from the circular support frame; and

a ceiling tile defining a straight edge engaged with one of plurality of T-shaped frame members.

2. The drop ceiling according to claim 1 where in the ceiling tile defines a curved edge engaged with the circular support frame.

3. The drop ceiling according to claim 1 wherein the circular support frame has an L-shaped cross-section.

4. The drop ceiling according to claim 1 wherein the circular support frame has a T-shaped cross-section.

5. The drop ceiling according to claim 1 wherein the circular support frame is coupled between adjacent straight frame members.

6. The drop ceiling according to claim 1 wherein the circular support frame is supported using support wires.

7. The drop ceiling according to claim 1 wherein the circular support frame is coupled to the T-shaped frame members using a flange in slot coupling mechanism.

8. The drop ceiling according to claim 1 further comprising a cover disposed within the circular support frame.

9. The drop ceiling of claim 1 wherein the T-frame member is formed from a single sheet metal strip.

10. The drop ceiling according to claim 1 further comprising a component at least partially disposed through the circular support frame the component selected from the group consisting of a light, a sensor, sprinkler head, a smoke detector, a camera.

11. Claim 10 where in the component is fixably coupled to the circular support frame.

12. A drop ceiling frame construction comprising:

a first T-shaped suspended frame member;

a second T-shaped suspended frame member coupled to the first T-shaped frame member at a 90 degree angle;

a curved support frame coupled to both the first and second T-shaped suspended frame members; and

a ceiling tile defining a first straight edge engaged with the first T-shaped frame members and a curved surface coupled to the curved support frame.

13. The drop ceiling according to claim 12 where in the ceiling tile defines a second straight edge engaged with the second T-shaped support frame. The drop ceiling according to claim 12 wherein the curved support frame has an L-shaped cross-section. The drop ceiling according to claim 12 wherein the curved support frame a curved support frame has a first coupling flange defined at a first end configured to engage the first T-shaped suspended frame member, and a second coupling flange configured to engage the second T-shaped suspension frame member.

16. The drop ceiling according to claim 15 wherein the first T-shaped support frame defines a coupling slot and the first coupling flange is disposed within the coupling slot.

17. The drop ceiling according to claim 16 wherein the second T-shaped support frame has a support surface and wherein the second coupling flange engages the support surface.

18. A drop ceiling frame construction comprising:

a curved support frame member having a radially disposed curved tile support flange and a body member defining a plurality of coupling slots;

a first plurality of T-shaped frame members;

a second plurality of T-shaped frame members each having a coupling flange coupled to one of the plurality of coupling slots, wherein said first and second plurality of T-shaped frame members defining a grid pattern.

19. The drop ceiling frame construction according to claim 18 wherein the curved support frame member is a circular member having a radially disposed support tile support flange

20. The drop ceiling frame construction according to claim 18 comprising a ceiling tile having a first straight edge coupled to one of the second T-shaped frame members, said ceiling tile defining a second curved surface engaged to the radially disposed curved tile support flange, and a component at least partially disposed through the circular support frame the component selected from the group consisting of a light, a sensor, sprinkler head, a smoke detector, a camera.