Note: Descriptions are shown in the official language in which they were submitted.
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SUSPENDED CEILING SYSTEM
Background of the Invention
This invention pertains to suspended ceiling systems, and
more particularly pertains to a suspended ceiling system
constructed from a lightweight, pliable material, such as extruded
or injection molded plastic, for suspension from an overhead
surface.
The home remodeling industry has increased dramatically
in recent years as more and more homeowners are taking matters
into their own hands when the decision is made to remodel or
redesign their dwellings. Among the primary remodeling projects
are adding rooms to a house, enlarging a kitchen to increase the
shelf space and cooking area, turning a cement basement into a
game room or family room, and installing a drop - or suspended -
ceiling to cover unsightly rafters, electrical conductors, and
duct work and provide an aesthetically appealing overhead surface
of ceiling tiles and lighting fixtures. Numerous chain and retail
stores sell the tools and equipment to engage in a home remodeling
project, and among the better known stores are Home Depot, S4
Lumber, Busy Beaver, K-Mart, and Wal-Mart.
The simplest type of suspended ceiling structure includes
metal wall angles for attachment to the walls of a room, metal
main runner members or cross-T's and metal cross braces for span-
ning the room and forming a grid beneath the overhead ceiling for
supporting ceiling tiles or panels within the grid formed by the
main runner members, cross-T's and cross braces. Various types of
hanger structures or devices are used to hang ~the runner members,
cross-T's and cross braces from the rafters or beams forming the
overhead ceiling.
There have been numerous improvements to the simple,
above-described suspended ceiling structure, and the improvements
have been in the materials out of which the structural components
21 93~62
are manufactured, improvements in the method or manner the various
structural components are joined to each other, and improvements
in the method or manner of suspending the structural components
from the overhead surface.
For example, U.S. Patent 3,768,224 discloses a sub-ceiling
grid system whereby the main runners and the cross runners are
interlocked together by splices for forming a clipless grid
system. U.S. Patent 4,281,498 discloses a wooden suspended
ceiling using locking blocks for attaching the cross beams to each
other. U.S. Patent 4,464,876 discloses a suspended woodbeam
ceiling in which the crossbeams are suspended by locking clips
and U-shaped connectors. U.S. Patent 4,454,700 also discloses a
suspended woodbeam ceiling with specially designed locking clips.
U.S. Patent 4,773,200 discloses a wooden suspended ceiling
system comprising wooden runners and cross members shaped to
interconnect with each other to form a rectangular grid system.
U.S. Patent 4,841,709 discloses a suspended ceiling system having
wooden main beams and cross beams connected together by wooden
blocks.
Other suspended ceiling structures include U.S. Patent
3,470,666 which utilizes a center beam from which ceiling tiles
can be erected in serial rows, the suspended ceiling system af
U.S. Patent 3,385,020 wherein wooden crosspieces and runners are
interconnected to form a grid system, and U.S. Patent 3,583,119
which discloses the utilization of simulated woodgrain risers
resting upon flanges of the grid members.
However, despite the ingenuity of the above suspended
ceiling systems, there remains a need for a suspended ceiling
system which is lightweight, easy to install, and requires only
the simplest of tools to assist in the installation.
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Summary of the Invention
The present invention comprehends a suspended ceiling
system which is suspended from an overhead surface or ceiling of
a room to create a grid therebelow for supporting ceiling tiles,
panels, lighting fixtures and the like.
The suspended ceiling system of the present invention
includes a plurality of wall trim members which are secured to
the walls of the room to form a perimeter around the room. A
plurality of elongated main runner members are secured to one wall
trim member in spaced-apart relationship to each other and then
are suspended from the ceiling. Successive main runner members
are then abutted to the ends of the main runner members which
extend from the wall trim member and then they are also suspended
from the ceiling. The main runner members are disposed end-to-end
so that they span the room and the last row of main runner members
abut the wall trim member secured to the opposite wall. A
plurality of cross braces are then disposed so as to interlock
or interfit with the main runner members perpendicularly thereto
to form a grid beneath the ceiling for supporting tiles, panels,
lighting fixtures and the like. The wall trim members, main
runner members and cross braces are suspended from the ceiling
in the same horizontal plane.
The suspended ceiling system of the present invention
utilizes an adjustable hanging means to suspend the main runner
members and the cross braces from the ceiling. The hanging means
includes a plurality of clips which are capable of slidable,
adjustable, linear movement on the main runner members and the
cross braces so that the clips can be properly positioned thereon
for suspending the main runner members and the cross braces from
the ceiling. Each clip includes a pair of opposed sidewalls, each
of which includes a centrally-located notch, a top flat, horizon-
tal surface portion and an arched member projecting upwardly
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therefrom. The arched member further defines an aperture through
which a wire can be inserted. The other end of the wire can be
attached to a fastener, such as a wood screw, drilled into an
overhead joist or beam of the ceiling. The clips have four
purposes: 1) to attach the end portions of the main runner
members to the flat, vertical portions of the wall trim members;
2) to support from the overhead ceiling the main runner members
in their horizontal extension across the room; 3) to connect cross
braces to main runner members at intersection points in the grid;
and 4) to span and connect together the end portions of two
abutting main runner members.
An alternate embodiment is adapted for a suspended ceiling
framework already in-place beneath an overhead ceiling and which
comprises a plurality of L-shaped metal wall angles secured to
the walls of the room to form a perimeter thereon, a plurality
of elongated, inverted, T-shaped metal main runners which extend
from the metal wall angle secured to one wall and span the room
for attachment to the metal wall angle secured to the opposite
wall, and a plurality of elongated, inverted, T-shaped cross
braces which interconnect with and are disposed perpendicular to
the metal main runners to form a grid beneath the ceiling for
receiving ceiling tiles, panels, lighting fixtures, and the like.
The alternate embodiment is designed to give a wood finish
or wood grain appearance to the suspended ceiling framework by
providing structural members which completely cover the metal
structural elements of the in-place suspended ceiling framework.
The structural members include a plurality of elongated
wall trim cover members which rest upon and cover the L-shaped
metal wall angles, a plurality of elongated, generally V-shaped
main runner covers members which rest upon and completely cover
the T-shaped metal main runners and a plurality of elongated,
generally V-shaped cross brace cover members which rest upon and
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21 93762
completely cover the T-shaped metal cross braces. Thus, when the
structural members of the alternate embodiment are disposed on
the elements of the suspended ceiling framework, a person standing
in the room and looking up at the ceiling would see a wooden
suspended ceiling grid supporting and framing ceiling tiles and
panels, and not the metal structural elements comprising the
suspended ceiling framework.
The alternate embodiment also includes a plurality of
inside and outside cover members which are disposed to rest upon
and cover the end portions of the metal wall angles that meet at
the inside or outside right-angled corners of the room or rooms.
It is an objective of the present invention to provide a
suspended ceiling system which is lightweight, flexible, and easy
to install in rooms of varying dimensions.
It is another objective of the present invention to
provide a suspended ceiling system which includes an adjustable
hanging means for suspending the system beneath an overhead
surface in a horizontal plane.
Yet another objective of the present invention is to
provide a suspended ceiling system which requires the simplest
of tools for installation.
Still another objective of the present invention is to
provide an alternate embodiment for covering the metal structural
components of an in-place suspended ceiling framework in order
to provide a simulated wood appearance for individuals standing
in the room and looking up at the suspended ceiling framework.
Other features of the invention and the advantages
presented thereby will become apparent as the description herein
proceeds.
Brief Description of the Drawings
Fig. 1 is an isometric view of the first preferred embodi-
ment of a susp'ended ceiling system with structural components
broken away and taken in section;
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Fig. 2 is an enlarged fragmentary front elevational view
of the suspended ceiling system first shown in Fig. 1 illustrating
a main runner meml)er with a clip attached thereto;
Fig. 3 is an enlarged fragmentary view of the suspended
ceiling system first shown in Fig. 1 illustrating a cross brace
interlocking with a main runner member with a clip attached to
the main runner member;
Fig. 4 i~i an enlarged fragmentary side elevational view
of the suspended ceiling system first shown in Fig. 1 illustrating
a main runner member abutting a wall trim member and secured in
place with a clip;
Fig. 5 is a top plan view of the suspended ceiling system
first shown in Fig. 1 illustrating the grid formed beneath the
overhead surface by the suspended ceiling system;
Fig. 6 is an isometric view of an alternate preferred
embodiment of the system first shown in Fig. 1 illustrating an
improvement for covering an in-place metal suspended ceiling
framework;
Fig. 7 is an isometric view of the improvement first shown
in Fig. 6 illustrating the improvement as it would appear from a
vantage point located beneath the suspended ceiling framework;
Fig. 8 is a top plan view of the improvement first shown
in Fig. 6 illustrating the placement of one inside cover member
and one outside cover member on respective metal wall angles;
Fig. 9 is a top plan view of the improvement first shown
in Fig. 8 illustrating the use of an inside cover member, an
outside cover member, and wall trim members of various lengths,
some of which have one reduced end portion;
Fig. 10 is an enlarged perspective view of a main runner
cover member first shown in Fig. 6 illustrating a plurality of
inwardly-facing tabs for resting upon the flanges of the inverted
T-shaped metal main runners; and
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Fig. 11 is a fragmentary bottom plan view of the improve-
ment first shown in Fig. 6 illustrating main runner cover members
and corss brace cover members having tapered or V-shaped end
portions that interlock at an intersection of the grid formed by
the suspended ceiling framework.
Detailed Description of the Preferred Embodiment
Illustrated in Figs. 1-5 is a suspended ceiling system 10
for suspension from an overhead ceiling or surface. The system 10
is spaced from the overhead ceiling and forms a grid 12 therebelow
for supporting light fixture panels, air filter modules, blank
panels, ceiling tiles 14, etc. The room should have at least two
opposed walls for supporting the grid 12 formed by the suspension
of the system 10, and, typically, the suspended - or drop -
ceiling system 10 will be disposed in a game room or basement to
brighten and enhance the appearance of those respective rooms.
The system 10 illustrated in Figs. l-S may be constructed out of
wood or out of a plastic material such as pvc, styrene, or
polyethylene; but the material should be lightweight, pliable and
easy to lift and manipulate by one individual.
As illustrated in Figs. 1-5, the system 10 of the present
invention includes a plurality of elongated wall trim members 16
which are secured to the walls of the room. Fig. 1 illustrates
two adjacent walls 18 and 20. The members 16 are secured to the
walls 18 and 20 by any of a variety of fasteners 22, such as wood
screws, anchor screws, or toggle bolts, and the members 16 are
disposed the same distance from the ceiling to form a perimeter on
the walls 18 and 20. As illustrated in Figs. 1 and 2, the members
16 have a unique profile which facilitates the installation of
the system 10 and allows simple and quick joining and connection
to other structural elements hereinafter further described. Thus,
each member 16 includes a flat, elongated vertical portion 24
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having a rear surface 26 which is contiguous with the respective
wall 18 or 20 and a facing surface 28 which faces inward toward
the room when the members 16 are secured to the walls 18 and 20.
A flat, elongated horizontal portion 30 is integrally joined to
the portion 24 to form an L, and an upwardly-facing surface 32 of
the portion 30 is adapted to receive and support thereon edges 34
of the tiles 14 as well as other structural elements hereinafter
further described.
In addition, each member 16 includes a flat, elongated
downwardly-projecting portion 36 which is coequal in length or
extension with the horizontal portion 30 and vertical portion 24.
The portion 36 is integrally attached to the portion 30 at an
upper end and, further, the portion 36 has a lower end which
projects downwardly away from the ceiling and toward the floor.
Finally, each member 16 includes a molded portion 38 which is
coequal in length with the vertical portion 24, the horizontal
portion 30, and the downwardly-projecting portion 36. The portion
38 also includes a lower molded end 40 which abuts the wall 18
or 20 to which the member 16 is secured as shown in Fig. 1. The
molded portion 38 can be shaped or formed into any number of
different profiles; the profiles shown in Figs. 1 and 2 are only
one example, and there can be many others. In order to keep the
members 16 as lightweight and flexible as possible for ease and
simplicity of installation, the dimensions have been kept to a
minimum: the width of the portion 24 is approximately 3/16 of an
inch and the width of the surface 32 is approximately 3/8 of an
inch while the length of the portion 36 is also approximately 3/8
of an inch. It should also be noted that the portion 36 presents
a flat surface 42 against which structural elements hereinafter
further described can be butted against.
As illustrated in Figs. 1-5, the system 10 also includes
a plurality of elongated main runner members 44 which are disposed
in the same hori'zontal plane beneath the ceiling for spanning the
21 93762
room from one member 16 to the opposite member 16. Each member
44 includes a pair of oppositely-disposed, horizontally-projecting
arms 46 which are coequal in length with the respective member 44.
Each member 44 terminates at a pair of oppositely-disposed, flat,
vertical end portions 48; it is the end portions 48 which abut
the surface 42 as shown in Fig. 1. Each arm 46 includes a flat
receiving surface 50 upon which the edges 34 of the ceiling tiles
14 will rest when the grid 12 is disposed beneath the ceiling
and the ceiling tiles 14 are placed within and supported by the
grid 12. Further, as shown in Fig. 1, each member 44 includes
an upraised, inverted, generally V-shaped or mushroom-shaped
runner portion 52 which is coequal in length with the arms 46 and
terminates at the opposed end portions 48. In addition, a channel
or groove 54 is formed on each member 44 at the point where the
runner portion 52 extends upwardly from each arm 46. The channel
54 may be no deeper than 3/32 of an inch, but it is necessary so
that a structural element hereinafter further described can be
properly attached to the runner portion 52.
In addition to the members 44 shown in Figs. 1-5, the
system 10 includes a plurality of elongated cross braces 56 which
are attached and interlocked to the members 44 at right angles to
form the grid 12 beneath the ceiling for supporting the tiles 14.
Each cross brace 56 includes a pair of oppositely-disposed,
horizontally-projecting cross brace arms 58 which are coequal in
length with the main body portion of the cross brace 56. Each
arm 58 further defines an upwardly-facing flat surface 60 for
receivlng and supporting thereon ceiling tiles 14, panels and the
like. Furthermore, similar to the members 44, the cross braces
56 include an upraised, inverted, generally mushroom-shaped or
V-shaped portion 62 which is located between each arm 58 and
projects upwardly therefrom a short distance. Moreover, as
illustrated in Fig. 1, each cross brace 56 includes a pair of
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oppositely-disposed, elongated rabbets 64 which extend the length
of the cross brace 56 and are formed in the area where the portion
62 projects upwardly from each arm 58. In order to attach and
interlock the cross braces 56 to the members 44, each cross brace
56 includes oppositely-disposed notched or coped ends 66 for
interlocking with the arms 46 as shown in Fig. 3.
In order to properly suspend the system 10 from the
overhead surface, an adjustable hanging means is employed for
properly suspending the members 44 and the cross braces 56 from
the overhead surface as well as performing several other functions
which will be hereinafter further described. The adjustable
hanging means of the present invention includes a plurality of
clips 68 which can be attached to the cross braces 56 and the
members 44 and which are capable of slidable, linear, reciprocal
movement on the cross braces 56 and members 44 so that the clips
68 can be properly positioned thereon in order to suspend the
system 10. Also, the clips 68 facilitate the suspension of the
cross braces 56 and the members 44 from the overhead surface in
a level, spaced-apart disposition so that the grid 12 will lie
in the same horizontal plane and be spaced an equal distance from
the overhead surface.
As shown in Figs. 1-4, each clip 68 includes a flat,
horizontal surface portion 70 and a pair of spaced-apart,
oppositely-disposed, vertical sidewalls 72 integrally attached
to and depending from the surface portion 70. In addition, each
sidewall 72 includes a centrally-located notch 74 adjacent its
lower edge, and the notch 74 of one sidewall 72 is aligned with
and has the same dimensions as the notch 74 of the opposed
sidewall 72. Further, each clip 68 includes an arched member 76
which projects slightly above the surface portion 70 and which
defines an aperture 78 between the arched member 76 and the
surface portion 70. A chain or wire 80 can be looped through the
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aperture 78 for suspending the clips 68 from the overhead surface.
Furthermore, the lower end of each sidewall 72 terminates with
a row of serrated teeth 82 which slightly dig into the projecting
arms 46 and 58 and the runner portions 52 and 62 as well as the
upwardly-facing surfaces 32 so as to prevent the clips 68 from
sliding when positioned on these structural elements. By pressing
down on the clips 68, the teeth 82 can dig slightly into the
members 16 and 44 and the cross braces 56. More specifically,
as shown in Figs. 1 and 2, the sidewalls 72 of each clip 68 abut
and enclose the runner portions 52 and 62 and the cross braces
56. The sidewalls 72 are flexible and can be pushed down upon
the runner portions 52 and 62, and their pliability allows the
sidewalls 72 to spread outward and conform to the shape of the
runner portions 52 and 62. The lower ends of the sidewalls 72
then slightly project into the channels 54 and the rabbets 64,
and this prevents the clips 68 from lifting off of the members
44 and cross braces 56 when the clips 68 are disposed thereon for
suspension from the overhead surface by the wires 80, one of which
is illustrated in Fig. 1.
As illustrated in Fig. 1, the clips 68 have four purposes
which facilitate the suspension of the system 10 from the ceiling.
The clips 68 can be used to attach a member 44 to a member 16 by
pressing the clip 68 onto the runner portion 52 of the member 44
and then sliding the clip 68 so that half of both sidewalls 72
project past the end portion 48. The lower ends of the sidewalls
72 can then rest upon the upwardly-facing surface 32. This is
shown in Fig. 4. The clips 68 can also support the members 44 in
their horizontal extension across the room by attaching clips 68
to the runner portions 52 and then looping a portion of the wire
80 through the aperture 78 or tying one end of the wire 80 to the
arched member 76 and then attaching the other end of the wire 80
to a fastener which is drilled into the ceiling. A third purpose
, . -13- 21 93762
of the clips 68 is to connect a pair of cross braces 56 to a
runner member 44 at an intersection point in the grid 12. The
coped ends 66 of two adjacent cross braces 56 are interlocked with
the arms 46 of one runner member 44, as shown in Figs. 1 and 3,
and then one clip 68 is pressed down upon the runner portion 52 of
the member 44 so that the notch 74 of the clip 68 receives the
runner portion 52 and the teeth 82 dig into the flat surface of
the arms 58. Finally, the clips 68 are used to span and connect
two adjacent runner members 44 so that the end portion 48 of one
runner member 44 is abutted against the end portion 48 of an
adjacent runner member 44. In this case, one clip 68 is pressed
down upon the runner portion 52 of an already suspended main
runner member 44 and then the clip 68 is slid forward so that
approximately half of the clip 68 projects past the end portion
48 of that main runner member 44. Then the next runner member
44 is lifted up and aligned so that its runner portion 48 will
slide between the sidewalls 72 of the already attached clip 68.
The individual then pushes this runner member 44 so that its end
portion 48 abuts the end portion 48 of the already suspended
runner member 44. The clip 68 now spans, connects, and suspends
the end portions 48 of two abutting main runner members 44.
There are many ways of installing the suspended ceiling
system 10 of the present invention in, for example, a gameroom
or a basement. What follows is one example of a description of
the steps or procedures required to install the system 10 in such
a room. The tools necessary for the installation are a tape
measure, a utility knife, a hammer, along with fasteners, such
as various types of screws, and lengths of wire or wire loops for
suspending the grid 12 from the overhead ceiling or surface. In
addition, a miter saw may be required if two walls meet at a
beveled angle.
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The first step in installing the system 10 is to measure
on all the walls a fixed distance down from the ceiling on each
of the respective walls. Light pencil or chalk marks should mark
this distance, and then a horizontal line should be lightly drawn
or placed on each wall so that the lines form a perimeter on the
respective walls. The lines should be in the same horizontal
plane and should all be the same distance from the ceiling, or,
conversely, from the floor. Next, the members 16 should be secured
to the respective walls, two of which are shown in Fig. 1 and
denoted by reference numbers 18 and 20, by placing the members 16
against the walls 18 and 20 and on the respective horizontally
drawn lines. A wide variety of fasteners 22 can be used to secure
the members 16 to the walls 18 and 20 depending upon the
composition of the walls and the framework supporting the wall.
lS For example, wood screws can be drilled through the vertical
portion 24 of the members 16 and into studding supporting the
walls 18 and 20. As shown in Fig. 1, the wood screws should be
equidistantly spaced along the vertical portions 24 and a
sufficent number of wood screws should be used so that the rear
surface 26 of vertical portions 24 is continuous with the walls 18
and 20 and there are no gaps between the walls 18 and 20 and the
members 16. The standard length of the members 16 is eight feet,
and members 16 should be secured to all the walls. A utility
knife or a miter saw can be used to cut or miter the ends of
members 16 where two members 16 meet at a corner of the room which
is not a right angle. The members 16 have a very thin profile,
and if a standard length member 16 is too long for the wall, the
member 16 can be easily cut by a utility knife or a miter saw.
Once the members 16 are secured to the respective walls
of the room, the next step is to start the extension of the main
runner members 44 from one member 16 so that the members 44 span
the room and reach the member 16 secured to the opposite wall.
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Clips 68 are attached to the end portions 48 of the initial main
runner members 44 so that approximately half of each clip 68
overhangs or projects out from the end portions 48. The initial
main runner members 44 are then butted against the flat surface 42
of the portion 36 of the members 16. The lower ends of the
overhanging halves of the clips 68 rest upon the surface 32 of the
horizontal portion 30 of the member 16. These clips 68 can be then
secured to the ceiling by the use of wire 80 looped around and tied
to the arched members 76 and fasteners and other clips 68 can be
attached along the runner portions 52 of the initial main runner
members 44 for attachment to the ceiling through the use of wire
80 attached to fasteners inserted into the ceiling. The initial
main runner members 44 should project from the member 16 in the same
horizontal plane and should be spaced an equal distance from each
other.
After suspension of the initial or starting main runner
members 44 from the ceiling, the next step is to abut as many runner
members 44 as is necessary, one after another, to the starter main
runner members 44 until the room is spanned and the member 16
secured to the opposite wall is reached. Main runner members 44 may
come in lengths of eight or ten feet so in a basement or gameroom
it may require no more than two members 44 to span the room while
for a department store, for example, a half dozen members 44 may
be needed to span the room from one wall to the opposite wall. The
members 44 are placed one after another in linear succession in the
same horizontal plane until the room is spanned, and the end portion
48 of one main runner member 44 abuts the end portions 48 of the
next member 44. As each line of members 44 is installed, clips 68
may be attached to the runner portions 52 along the length thereof
as desired to support the members 44 in their suspension from the
ceiling.
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If the distance between the next-to-last runner members
44 and the member 16 secured to the opposite wall is not eight or
ten feet, then the installer can simply measure the distance between
the end portions 48 of the row of next-to-last runner members 44 and
the flat surface 42 of the portion 36 of the opposite member 16 and
then cut the last main runner members 44 so that they span this
distance. A straight cut is all that is required since clips 68
are used to span and attach the end portions 48 of the members 44
to the members 16. The profile of the members 16 above the molded
portion 38 makes any special coping or notching of the end portions
48 unnecessary as the end portions 48 simply abut the flat surface
42 of the portion 36 of the members 16. The next step is to mount
the cross braces 56 at right angles to the remaining two members
16 secured to the other two walls and also to the members 44 at
regularly spaced intervals to complete the grid 12 beneath the
ceiling.
As illustrated in Figs. 1, 3, and 5, the initial cross
braces 56 are secured to one of the two members 16 which are not
abutted by a main runner member 44. Clips 68 are used to attach
the initial cross braces 56 to the member 16 in the same manner as
the clips 68 were used to attach the members 44 to the members 16.
The notched or coped end 66 of the cross braces 56 are interlocked
or interfitted to the projecting arms 46 of a first adjacent row
of members 44 and then clips 68 are attached to the runner portions
62 adjacent the coped ends 66 of the cross braces 56 while the
notches 74 of the clips 68 accommodate the runner portions 52 of
the members 44. Cross braces 56 are interlocked to an initial row
of members 44 in this manner. The coped end 66 of the next cross
brace 56 is then interlocked to the free projecting arm 46 of the
first main runner member 44 of the first adjacent row and the arm
46 of the starter main runner member 44 of the next adjacent row.
In order to keep the cross braces 56 in place, clips 68 are attached
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to the ends 66 of the cross braces 56 so that the sidewalls 72
encompass the runner portions 62. The notches 74 of the clips 68
accommodate and allow passage therethrough of the runner portions 52
of the runner members 44 and then the other half of the clips 68
slide down upon and contain the runner portions 62 of the next line
of cross braces 56. In this way one clip 68 secures the connection
between the ends 66 of two cross braces 56 and the projecting arms
46 of the runner members 44.
To further secure the clips 68 in place, wires 80 are then
attached to or looped around the arched members 76 and then attached
to respective fasteners inserted in the ceiling. One after another
the cross braces 56 are interfitted to the rows of main runner
members 44 so that the grid 12 is formed as shown in Fig. 5. The
cross braces 56 are coped at both ends 66 and will generally come
in lengths of two or four feet; however, if the distance between
either the first or last rows of main runner members 44 and the
adjacent members 16 is a non-standard distance, then the last series
of cross braces 56 can be cut to span that distance. Since the
members 16 do not require any special coped end for either the
members 44 or the cross braces 56 to attach thereto, a straight cut
can be made adjacent one of the coped ends 66 of the cross braces 56
and the straight cut end of the cross braces 56 can be abutted up
against the flat surface 42 of the portion 36 of the member 16 while
the opposite coped ends 66 of the cross braces 56 can be interfitted
to the arms 46 of that first or last row of main runner members 44.
Clips 68 can be then attached to the runner portions 62 of the cross
braces 56 so that at least one clip 68 attaches the coped ends 66
of the cross braces 56 to the arms 46 of the members 44 while other
clips 68 will span the straight cut ends of the cross braces 56 to
partially rest upon the upwardly-facing surfaces 32 of the horizon-
tal portions 30 of the members 16 in order to connect and support
the cross braces 56 to the members 16. Clips 68 can be attached
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to any of the cross braces 56 and members 44 to provide additional
support for the grid 12. In addition, the clips 68 can be slid
along the runner portions 52 and 62 to better position the clips
68 before they are attached by some type of flexible wire means
to the ceiling. Finally, the ceiling tiles 14, panels, lighting
fixtures, and the like can be disposed within the grid 12 by
placing the edges 34 on the receiving surfaces 50 of the arms 46
of the members 44, on the flat surfaces 60 of the cross brace arms
58, and on the surfaces 32 of the members 16. This completes one
method or manner of installing the drop or suspended ceiling
system 10 of the present invention.
Illustrated in Figs. 6-11 is an alternate embodiment for
the suspended ceiling system 10. The alternate embodiment is
adapted for use with a suspended or drop ceiling framework 84
already in place and suspended from an overhead surface or
ceiling. The following structural elements are used to support
ceiling tiles 86 and panels in the typical framework 84: a
plurality of L-shaped metal wall angles 88 which are secured to
the walls 90 and 92 of the room to form a perimeter thereon, a
plurality of elongated, inverted, T-shaped metal main runners 94
which extend from the wall angle 88 which is secured to one wall
and which spans the room to the wall angle 88 secured to the
opposite wall and a plurality of elongated, inverted, T-shaped
cross braces 96 which are disposed perpendicular to the main
runners 94 and either rest upon or interconnect thereto in some
manner to form a grid beneath the ceiling for receiving ceiling
tiles 86, panels, lighting fixtures, and the like. When tiles
86 or panels are placed on the framework 84, the metal structural
elements will not be covered up but will be viewable to anyone
standing in the room and looking upward at the drop ceiling.
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The alternate embodiment is designed to give a wood grain
appearance to the in-place framework 84 by providing structural
members which are removably attachable to and which completely
cover the framework 84. In addition, the structural members of
the alternate embodiment can be colored to meet the purchaser's
specifications. The structural elements of the alternate embodi-
ment are manufactured from a lightweight, pliable material such
as pvc, styrene, or polyethylene, and the only tool needed for
installation of the alternate embodiment is a utility knife.
As shown in Figs. 6-11, the alternate embodiment includes
a plurality of elongated wall trim members 98 which are attached
to the wall angles 88. Each member 98 includes a flat, horizontal
surface portion 100 for resting upon the horizontal leg of the
wall angles 88, a flat, vertical surface portion 102 which depends
from and is integrally attached to the surface portion 102, and
a molded portion 104 which is integrally attached to the surface
portion 102 and which abuts the wall 90 or 92 to which the wall
angles 88 are secured. The profile or contour of the molded por-
tion 104 can vary widely; the molded portions 104 shown in Figs. 6
and 7 are an example of one particular contour. The members 98
will come in standard eight foot long pieces and, for walls
shorter than eight feet, the members 98 can easily be cut with
a utility knife to fit on such walls.
Illustrated in Figs. 6 and 7 are a plurality of elongated,
generally V-shaped main runner cover members 106 for attachment
to horizontally-projecting lips or flanges 108 of the main runners
94. More specifically, each cover member 106 includes opposed,
straight, vertical ends 110 and a pair of elongated, opposed,
integrally-turned flanges 112 which are slid onto the flanges 108.
As shown in Figs. 6 and 7, the flanges 112 are flat, horizontally-
projecting structural members integrally attached to the cover
members 106 and coequal in length therewith.
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As illustrated in Figs. 6 and 7, the alternate embodiment
also includes a plurality of elongated, generally V-shaped cross
brace cover members 114 for sliding onto lips or flanges 116 of
the braces 96 so that the braces 96 are completely covered by the
cover members 114. Each cover member 114 includes straight,
vertically-cut, opposed cover ends 118 and a pair of elongated,
opposed, inwardly-turned cover flanges 120 for sliding onto the
flanges 116 and thus attaching the cover members 114 to the braces
96. The flanges 120 are flat and horizontally-projecting.
In addition, the alternate embodiment includes a plurality
of joint cover members 122 as shown in Fig. 7. The cover members
122 have the shape of a plus sign and include four pairs of
inwardly-turned, flat, horizontally-projecting flanges 124 with
one pair of flanges 124 for each arm 126 of the cover members 122.
Each cover member 122 is disposed to cover the intersection points
of the grid where one pair of cross braces 96 intersects one main
runner 94 at a right angle or the gap formed where one main runner
94 follows or precedes another main runner 94 in their extension
across the room and also where two cross braces 96 meet at the
main runners 94 and are connected perpendicularly thereto. The
cover members 122 are adapted to fit over the flanges 108 and 116
to cover the slight gaps formed where these structural members are
joined together in the framework 84 so that an individual viewing
the drop ceiling will see a continuous wood grain grid.
In addition, the alternate embodiment includes structural
members which are adapted to cover the end portions of two wall
angles 88 which meet at the corner of a room as illustrated in
Fig. 7. Fig. 7 illustrates two wall angles 88 which meet at an
inside right angle corner of the room; however, wall angles 88
could meet at a right angle - or any angle - on an inside or
outside wall of a room or rooms. Therefore, the alternate
embodiment of the present invention includes a plurality of
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right-angled inside cover members 128 which include a main body
portion and opposed ends 130, and a flat, inwardly-turned, contin-
uous, right-angled flange 132 which slides onto the horizontal leg
of the wall angles 88. In addition, as illustrated in Fig. 8,
the alternate embodiment also includes a plurality of outside
cover members 134 which include a main body portion and opposed
end portions 136, and a flat, horizontally-projecting, continuous
lip or flange 138 which is adapted to slide onto the horizontal
leg of the wall angles 88 for covering the ends of a pair of wall
angles 88 that meet at a right angle on an outside corner of the
room.
The shape and configuration of the above-described struc-
tural members of the alternate embodiment can be slightly modified
to facilitate ease of installation and to provide a continuous
simulated wood grain covering for the framework 84. For example,
the surface portion 100 of trim members 98, and the flanges 112
and 120 of both cover members 106 and 114, can be replaced by
structure similar to that shown in Fig. 10. Fig. 10 shows a cover
member 106 having the same general profile as the cover members
106 shown in Fig. 6, except that the flanges 112 shown in Fig. 6
have been replaced by a plurality of opposed, inwardly-facing,
spaced-apart main runner tabs 140 which slide onto the opposed
flanges 108 of main runners 94 and which rest thereupon when the
cover members 106 of Fig. 10 are attached to the main runners 94.
The cover members 114 illustrated in Fig. 6 may also have
their flanges 120 replaced by a plurality of opposed, inwardly-
facing, spaced-apart cross brace tabs similar to the tabs 140
shown in Fig. 10. The cross brace tabs would slide onto the
opposed flanges 116 and would permit the cover members 114 to rest
thereupon. In addition, the surface portion 100 may be replaced
by a plurality of flat, horizontally spaced-apart tabs for sliding
onto and resting upon the horizontal legs of the wall angles 88.
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The tabs should be at least as wide as the cover members 106. The
tabs 140 would be spaced several inches or so apart and would
replace the flanges 112 and 120 shown in Figs. 6 and 7 if the
cover members 106 and 114 are manufactured through an injection
molding process as opposed to an extrusion process for the flanges
112 and 120. The same will hold if tabs are used to replace the
surface portions 100.
Figs. 9 and 11 illustrate several other variations to the
structural members of the alternate embodiment which are designed
to avoid any overlapping of one structural member with another
during the process of covering the framework 84 and for providing
a close fitting at intersection points on the grid.
With reference to Fig. 9, modifications to the members 98,
128, and 134 are shown. With regard to the cover members 128 and
134, the modification includes shrinking down and extending the
size of the flanges 132 and 138 adjacent the opposed end portions
so that they have a configuration of a rectangular tab 142 and
have a width slightly less than that of the flanges 132 shown in
Fig. 7. The width of the rectangular tabs 144 would also be
slightly less than the width of the flanges 132 shown in Fig. 7.
For both cover members 128 and 134, the tabs 142 and 144 would
rest upon the horizontal legs of adjacent wall angles 88 as shown
in Fig. 9.
In addition, as illustrated in Fig. 9, at least one end
portion of each member 98 can include a rectangular tab 146. The
tab 146 would project outward from and in the same plane as the
surface portions 100 and would have a width slightly less than
that of the surface portions 100. Thus, as illustrated in Fig. 9,
the straight-cut end portion of one member 98 would overlap the
tab 142 or 144 while the tab 146 of that member 98 would be
disposed underneath the straight-cut end portion of the next
abutting member 98. The placement of the straight-cut end portion
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of one member 98 superjacent to the tab 146 of an adjacent and
abutting member 98, or the tabs 142 and 144 of cover members 128
and 134, permits a tight and close fitting for members 98, 128,
and 134 when they are all disposed in linear succession on one
or more wall angles 88. Also, this variation closes gaps between
members 98, 128, and 134, and avoids raising the edges of the
ceiling tiles 86 that rest upon the surface portions 100 and the
flanges 132 and 138 of cover members 128 and 134.
Furthermore, as illustrated in Fig. 9, because the members
98 are manufactured from a lightweight, pliable plastic, they can
be cut with a utility knife to fit any odd space, such as the
space shown in Fig. 9, whereby a gap between one cover member 134
and one member 98 remains to be filled. In order to cover this
area on the wall angle 88, the installer can simply make a
straight cut with a utility knife at both end portions 148 so that
the member 98 is cut to the appropriate length, and then the
installer can slide the surface portion 100 over the horizontal
leg of the wall angle 88 covering the tab 144 of cover member 134
and the tab 146 for the adjacent member 98. Therefore, members
98 and cover members 128 and 134, illustrated in Figs. 6 and 7,
as well as the variation illustrated in Fig. 9, will cover in one
continuous uninterrupted line, without gaps or upraised sections,
walls of any width as well as structures wherein adjacent or
adjoining rooms form inside and outside corners of varying angles.
Finally, the end portions of both cover members 106 and
114 shown in Figs. 6 and 7 can be altered to a tapered or V-shaped
configuration as illustrated in Fig. 11. V-shaped end portions
150 would obviate the need for cover members 122 shown in Fig. 7
as the intersection points on the framework grid would be covered
by the joining or interlocking of the end portions 150. In order
to start cover members 106 and 114 from the surface portions 102
of the members 98, the installer would simply make a straight cut
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on one V-shaped end portion 150, thus eliminating it and providing
a straight edge for abutment against the surface portion 102 of
the member 98.
The foregoing is a description of a preferred embodiment
and several alternate embodiments of the present invention. The
present invention, in its preferred embodiment and also in its
alternate embodiments, is not to be taken as limited to any of
the specific features as described, but comprehends all such
variations thereof as come within the scope of the appended
claims.
