Note: Descriptions are shown in the official language in which they were submitted.
CA 02557703 2006-08-28
WO 2005/094317 PCT/US2005/010397
FIBROUS FACED CEILING PANEL
Background
This disclosure relates to suspended ceiling systems and more particularly to
a
novel and improved system using perforated metal ceiling panels that include a
non-
woven fibrous facing material on the lower exposed surface of the panel
creating an
aesthetically pleasing and durable with fire safety qualities in a sound
absorbing
paneled ceiling system.
By way of background but not limitation, suspended-ceiling systems typically
include grid members that provide for oppositely extending ceiling panel
support
flanges. In these systems, the edges of the ceiling panels are installed by
laying them
in the panel opening created by the grid members. There are also suspended-
ceiling
systems that have grid members, which include channels designed to grip the
vertically extending edges of metal ceiling panels. These ceiling panels are
typically
installed by snapping the flanges up into the grid member channel, and are
generally
referred to as "snap-up ceiling panels." Typical lay-in grid panels are
manufactured
from slag wool fiber and/or recycled paper and expanded perlite or fiberglass
to create
light weight aesthetic ceiling panels. Some of these grid panels do not
provide
durability or sound absorption qualities that are desired for use in
commercial,
residential and industrial space.
In view of the above, it should be appreciated that there is a need for a
ceiling
panel that provides for increased durabilty and sound absorption. The present
disclosure satisfies these and other needs and provides further related
advantages.
Summary
The disclosure may be described as a novel and improved suspension ceiling
panel that includes enhanced sound deadening qualities and increased
durability. In
the preferred embodiment the panel comprises a metallic panel substrate
including a
plurality of apertures of varying sizes. The body is further adapted to be
connected to
the ceiling grid members. The outer exposed surface of the metallic panel
substrate is
covered by a non-woven fibrous material that is adhered thereto. The multi-
dimensioned apertures formed in the panel substrate in combination with the
non-
woven fibrous fabric on the lower exposed surface of the panel not only
provides the
appearance of a traditional acoustical panel but provides desirable sound
absorption
and resistance to flame spread and smoke generation.
CA 02557703 2006-08-28
WO 2005/094317 PCT/US2005/010397
Other features and advantages of the disclosure will be set forth in part in
the
description which follows and the accompanying drawings, wherein the
embodiments
of the disclosure are described and shown, and in part will become apparent
upon
examination of the following detailed description taken in conjunction with
the
accompanying drawings.
Brief Description of the Drawings
The above mentioned and other features of this disclosure and the manner of
obtaining them will become more apparent and the disclosure will be best
understood
by reference to the following description of embodiments of the disclosure
taken in
conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of one type of ceiling system illustrating
fibrous
faced ceiling panels;
FIG. 2 is a sectional view of the ceiling system, taken along lines 2-2,
illustrating the fibrous faced ceiling panels connected to a grid system;
FIG. 3 is a top view of the ceiling panel illustrating the spacing and sizes
of
the perforations;
FIG. 4 is a top view of the ceiling panel illustrating an alternate
perforation
pattern;
FIG. 5 is a perspective view of a ceiling system illustrating the fibrous
faced
ceiling panels transitioning from a first elevation to a second elevation;
FIG. 6 is another perspective view of a ceiling system illustrating the
fibrous
faced ceiling panels transitioning from a first elevation to a second
elevation;
FIG. 7 is a perspective view of a ceiling system illustrating the transition
from
the fibrous faced ceiling panels to other types of ceiling panels; and
FIG. 8 is a perspective view of a ceiling system illustrating curved fibrous
faced ceiling panels.
Detailed Description
While the present disclosure will be described fully hereinafter with
reference
to the accompanying drawings, in which a particular embodiment is shown, it is
to be
understood at the outset that persons skilled in the art may modify the
disclosure
herein described while still achieving the desired result. Accordingly, the
description
that follows is to be understood as a broad informative disclosure directed to
persons
skilled in the appropriate art and not as limitations on the present
disclosure.
2
CA 02557703 2006-08-28
WO 2005/094317 PCT/US2005/010397
As illustrated in the drawings, Fig. 1 illustrates a portion of an assembled
suspension ceiling incorporating snap-up fibrous faced ceiling panels 10 in
accordance with the present disclosure. In such a ceiling panel system, grid
members
12 are interconnected to form a grid structure 13. The grid members 12 are
arranged
to form openings 14 sized to receive the ceiling panels 10. The grid members
12 are
suspended from the building structure by wire hangers 16 or other supporting
structures.
To create the grid structure 13, a row of parallel evenly spaced grid members
12 are suspended by wire hangers 16. Each row of the grid members 12 are
spaced
apart to accommodate the size of the fibrous faced ceiling panels 10. To
accommodate a 2 foot by 2 foot ceiling panel, the grid members 12 would be
spaced
apart 2 feet on-center. The grid structure 13 also includes a second set of
grid
members 18 that are perpendicularly oriented in relation to the first set of
grid
members 12 to create the opening required for hanging the panels 10.
The fibrous faced ceiling panels 10 are normally rectangular, usually square
in
shape, and are preferably made out of metal. The panels 10 are durable in that
they
are impact resistant, self supporting do not sag or fracture when perforated.
Depending upon the ceiling design used, it may be desirable to shape the
panels 10
into a square or curved shape, as shown in Fig. 8, but other shapes may be
utilized.
Other shapes would include transition panels, as shown in Figs. 5 and 6, which
allow
the transition from a first elevation to a second elevation. Figure 7
illustrates a
decorative transition panel SS without the facer material, which can be a low
gloss or
high gloss, reflective panel. While the preferred material used in fabricating
the
fibrous faced ceiling panels 10 is metal, other materials may be used
including
gypsum, wood, wood fiber, plastic and other substrate materials that allows
perforation while retaining the basic shape and stiffness of the fibrous faced
ceiling
panels 10. Metal and plastic material, such as polycarbonate, are preferred
since
panels can be molded or stamped to include a desired shape or to form various
edge
configurations for connection to the grid structure 13. The fibrous faced
ceiling
panels 10 include an interior face 20 and an exterior face 22. The panels 10
may also
include a hinge 24 along a first corner 25 of the panel 10 to permit the panel
to be
pivoted to an open position with respect to the grid system 13. The panel 10
preferably includes flanges 26 along the edges 58 of the panel 10. While a
flanged
3
CA 02557703 2006-08-28
WO 2005/094317 PCT/US2005/010397
edge and a hinged edge are disclosed, other edge configurations may be used to
secure the panels 10 to the grid system.
The fibrous faced ceiling panels 10, as shown in FIG. 1, illustrates the
panels
connected to the grid structure 13 by use of flanges 26. It is beneficial to
use the
5 hinge 24 to support the ceiling panel 10 when all metal ceiling panels
become as large
as 4 feet by 4 feet, because the panels become awkward to install and remove
due to
their relatively large size and weight. Further illustrations of the use of a
hinge can be
found in U.S. Patent number 6,467,228, incorporated herein by reference. When
working with a piece of sheet metal with such a large surface, any improper
handling
10 may result in damage to the overall finish of the ceiling panel 10. Also,
by using the
hinge 24 that spans the length of the ceiling panel 10, the weight of the
panel is evenly
distributed across the entire corner 25 of the panel 10, preventing rippling
that would
be apparent in the bottom surface 20 of the panel 10. Furthermore, once the
ceiling
panel 10 is connected to the grid members 12, the ceiling panel 10 will
automatically
be in alignment to allow for easy closure by pivoting the ceiling panel 10
upward and
snapping in the flanges 26 into the grid.
FIG. 2 is a cross section of FIG. 1 taken along line 2-2 looking in the
direction
of the arrows and shows the grid member 12 and the hinge 24 along an corner 25
of a
first ceiling panel 10 and the flanged edge 26 of a second ceiling panel 10.
The grid
member in this example 12 is fabricated out of a single piece of die-formed
sheet
metal. The grid member 12 after fabrication includes a bulb portion 34, a
channel 36
and a double layer bridge portion 38 that connects the bulb portion 34 and the
channel
36. The overall shape of the grid member 12 is to give the member 12 strength
to
prevent flexing. Typically, apertures (not shown) are placed along the length
of the
bridge portion 38 so that wire hangers 16 can be threaded through and wrapped
around the bulb portion 34. Once the wire hanger 16, as shown in Fig. 1, which
can
be in the form of a wire, is threaded through an aperture (not shown) and
around the
bulb portion 34, the wire hanger 16 is wrapped around itself several times to
prevent it
from unraveling.
The bridge portion 38 typically includes slots (not shown) that allow one grid
member 12 to be connected to the second grid member 18 to form the grid
structure
13. The channel 36, as shown in FIG. 2 is formed by bending the double layers
of
the bridge portion 38, 90 degrees outward, 90 degrees downward and 90 degrees
inward to form a boxed channel 36. Bottom edges 42 are folded over to act as
an
4
CA 02557703 2006-08-28
WO 2005/094317 PCT/US2005/010397
engagement edge for the flange 26 and a retaining surface for the hinge 24.
The hinge
24 is formed in the ceiling panel 10 by die-forming the hinge 24 90 degrees
upward to
create an upwardly extending leg 43 and then die-forming the edge 90 degrees
inward
to create an inward lip 44. The inward lip 44 of the hinge 24 rests upon the
bottom
edge 42 in the channel 36 of the grid member 12. The flange 26, shown in FIG.
2, is
formed by die-forming or molding the edge 26 of the ceiling panel 10 upward 90
degrees to form a vertical member 45 and by forming a rib 48. The ceiling
panel 10 is
retained to the grid structure 13 by forcing rib 48 past the bottom edge 42.
The rib 48
is properly positioned within the channel 36 when the rib 48 is resting upon
the
bottom edge 42. The vertical member 45 biases the rib 48 to prevent the
ceiling panel
10 from moving out of position. While use of an edge with a rib 48 is
preferred, other
grid engagement mechanisms may be used including a lay-in arrangement wherein
the edges 26 do not include a flange.
Figure 2 also illustrates a fibrous facer material 54 adhered to the exterior
face
22 of the panel substrate 11 viewable from the environmental area of a
building
structure. The environmental area of the building structure is defined as the
space
within a building used by occupants to work or conduct other activities. It is
the
inhabitable space within a structure. From the environmental area, the fibrous
facer
material 54 is substantially exposed and viewable by the occupants below. The
interior face 20 of the panel 10 is substantially concealed from the
environmental area
and is not viewable by the occupants below. The fibrous facer material 54
creates an
aesthetically pleasing surface that gives the ceiling a soft appearance as
opposed to a
painted metallic ceiling panel, which has an undesirable shiny appearance.
Figure 3 is a top view of the fibrous faced ceiling panel 10 that illustrates
the
positioning of apertures 52 of a first diameter and apertures 53 of a second
diameter
across the panel 10. The non-woven fibrous facer material 54 on the exterior
face 22
of the panel 10 is adapted to cover the entire face 22 of the panel 10
including the
apertures 52, 53. When the fibrous facer material 54 is applied to the panel
10, only
the fibrous facer material 54 is visible from below. The panel substrate 11 or
the
apertures 52, 53 are not viewable from below. The sound absorption mechanism
of
the fibrous faced ceiling panels 10 is a combination of resonant absorber
sound
attenuation due to the resistance in air flow through the pores of the non-
woven
fibrous facer material 54 and the perforation of the panel 10. In order to
maximize
sound absorption at varying frequencies, three main parameters need to be
optimized.
CA 02557703 2006-08-28
WO 2005/094317 PCT/US2005/010397
This includes the extent of perforation of the panel 10 with apertures 52, the
airflow
resistance of the fibrous facer material 54 and the plenum height, i.e. the
distance
between the structure and the ceiling.
Figure 4 illustrates a top view of an alternate aperture arrangement wherein
the
panel 10 includes apertures 52 of a first diameter apertures 53 of a second
diameter
and apertures 55 of a third diameter. The combination of the three aperture
sizes
enhances the resistance of sound waves of varying frequency. The apertures 52
shown in figure 1 are all of a uniform size.
The extent of the perforation of the panel 10 is partially dependent upon the
strength of the selected substrate material and its resistance to mechanical
impact and
to excessive panel flex. Substrates such as metal and plastic can be
extensively
perforated, while gypsum board is limited to no more than about 20% of its
surface
area in order to maintain strength. In order to achieve the proper sound
deadening
qualities, the substrate is perforated from about 10% to about 35% open area.
Optimally, the percentage of the open area of the face 50 of the panel 10
should be
about 30% to about 33%
Sound is made up of various frequencies. A cymbal for instance would emit a
high frequency whereas a base drum would emit a low frequency. The varying
amplitude of the frequencies renders it difficult to provide a medium that is
sufficient
at deadening sound. A particular media may be efficient at capturing low
frequency
noise but is incapable of capturing high frequency noise. In order to enhance
sound
absorption at different frequencies the substrate panel 11 is perforated with
apertures
of different diameters. More specifically, two or three different aperture
sizes are
preferred. For the panel 10 to achieve the desired sound deadening qualities,
the
diameter of the apertures in the panel are from about .039 inches to about
0.117
inches to achieve the desired sound deadening qualities. Preferably, the
perforated
pattern is a combination of 15/128 of an inch apertures and 3/32 of an inch
apertures.
While circular apertures are preferred, oval triangular, polygonal, square or
elliptical
shaped apertures can also be used. Apertures with large diameters permit the
passage
of low frequency sounds with large amplitudes whereas apertures with smaller
diameters permit the passage of high frequency sounds with smaller amplitudes.
Spacing between the panels 10 is important in order to gain the maximum
benefits from the panels. In order to maximize the sound absorption qualities
of the
panels, it is sufficient that the gap tolerance between panels is in the range
from about
6
CA 02557703 2006-08-28
WO 2005/094317 PCT/US2005/010397
zero gap to about 3/8 of an inch and preferably from about a zero gap to a gap
of
about 1/4 of an inch. Spacing between the panels larger than 3/8 of an inch
permits
excessive sound to be deflected off of the grids 12 and back into the room,
reducing
the effectiveness of the ceiling system.
In testing of the panel 10 of the present disclosure smoke development and
flame spread by the panel resulted in values substantially lower than industry
standards. Limiting smoke development in a building fire is essential in order
to
increase the ability for occupants in the build to escape without being
subjected to
smoke inhalation. Typically in a fire, smoke inhalation, and not the fire
itself cause
death to the occupants.
The non-woven fibrous facer material 54 is applied to the panel substrate with
use of an adhesive. The adhesive utilized to adhere the non-woven fibrous
facer
material 54 to the ceiling panel 10 is preferably a hot melt adhesive that is
substrate
compatible. The adhesive must also be compatible with the type of facer
material 54
applied to the panel 10. While hot melt adhesive is preferred, it is
foreseeable that
other types of adhesives, such as spray, brush or roll-on adhesives may be
used. The
sound absorption qualities of the panel are also varied by the type and amount
of the
glue used on the fibrous facer material 54.
The panel substrate 11 and fibrous facer material 54 are designed to permit
molding or stamping of the panel 10 into desired configurations to create
flanges 26.
Transition panels 57, as shown in Figs. 5 and 6 or curved ceiling panels, as
shown in
Fig. 8 may also be created by molding or stamping the panel. Transition panels
57 are
used to transition from a first ceiling elevation to a second ceiling
elevation and can
be formed by bending or curving the panels 10. In order to permit the panel 10
to be
formed into the desired configuration, the panel substrate 11 is preferably
made from
steel, aluminum or polymer. The fibrous facer material 54 used to cover the
exterior
face 51 of the panel substrate 11 can be of various materials so long as the
material
does not rip or tear when formed with the panel. Certain materials when tested
such
as fiberglass tear or crack when the panel 10 is molded to create flanges 26
or other
desired shapes. Preferred materials for use as a fibrous face material 54
include
polymer mixtures having polyster fibers. Another such usable material is a
combination of NYLON6 and Polyethylene. Polymer mixtures of fibrous materials,
permit the passage of airflow through the material 54 and allow the panel 10
to be
CA 02557703 2006-08-28
WO 2005/094317 PCT/US2005/010397
shaped after the fibrous material 54 has been adhered to the panel 10 without
tearing
the fibrous face material 54.
To achieve the desired sound deadening qualities, the panel substrate 11, in
combination with the fibrous facer material 54 should have an airflow
resistance from
about 900 mks rayls to about 1050 mks rayls. Specific airflow resistance is
the
product of the airflow resistance of a specimen and its area. This is
equivalent to the
air pressure difference across the panel 10 divided by the linear velocity of
airflow
measured outside the panel 10. The airflow resistance of the fibrous facer
material 54
in combination with the perforated panel substrate is critical to the
efficiency of the
acoustic attenuation process. If the airflow resistance is too high, the
material reflects
the sound wave as if it were a solid wall. If it is too low, the sound wave
freely
travels through the material. In either case the sound attenuation is less
than
optimum. The preferred airflow resistance of the facer material 54 should be
about
100 mks rayls to about 600 mks rayls.
Airflow resistance of a panel 10 is defined as the ratio of the pressure drop
across the material to the velocity of the gas passing through it and can be
expressed
in cgs rayls (dyne/cm2 per cm/sec). Determination of flow resistivity is the
main
property in describing the acoustical performance of any porous material.
Every
fibrous material has specific flow resistance characteristics based on its
manufacturing
process or inherent nature. In the case of composite materials, such as the
present
panel 10, which is a combination of the fibrous facer material 54 and the
perforated
panel 10, it is important to understand the individual flow resistance of each
component. However, for optimum performance of the resultant panel 10, it is
vital
to tune the flow resistance of the entire system fibrous facer material 54 and
panel
substrate 11 to maximize sound absorption. As previously stated, this optimum
airflow resistance is about 900 mgs rayls to about 1050 mks rayls.
In most cases, plenum height 64 behind the panel 10 is limited and therefore
the sound absorption performance of the panel 10 is restricted by the short
plenum
gap, as shown in Fig. 2. In order to further enhance the sound absorption of
the panel
10 with a short plenum height a second layer of porous insulation material 56
such as
glass fiber, mineral fiber, thermoplastic polymeric fiber, thermosetting
polymeric
fiber, carbonaceous fiber, milkweed fiber, or foam insulation, (with
preference to
polyolefin microfiber melt blow products) can be applied to the interior face
20 of the
panel 10.
8
CA 02557703 2006-08-28
WO 2005/094317 PCT/US2005/010397
The panels 10 are designed with four edges 58 that are adapted to be
connected to the grid structure 13. The panels 10 can be connected to the grid
structure 13 using various edge configurations. The edges 58 of the panel 10
can
include the vertical member 45 and a rib member 48. This allows the panel to
be
snapped into the bottom edges 42 of the grid members 12 and 18. In yet another
alternative, the panel 10 does not include edges 25 and simply lays into the
openings
14 created by the grid structure 13.
While the concepts of the present disclosure have been illustrated and
described in detail in the drawings and foregoing description, such an
illustration and
description is to be considered as exemplary and not restrictive in character,
it being
understood that only the illustrative embodiments have been shown and
described and
that all changes and modifications that come within the spirit of the
disclosure are
desired and protected.
There are a plurality of advantages that may be inferred from the present
disclosure arising from the various features of the apparatus, systems and
methods
described herein. It will be noted that alternative embodiments of each of the
apparatus, systems, and methods of the present disclosure may not include all
of the
features described yet still benefit from at least some of the inferred
advantages of
such features. Those of ordinary skill in the art may readily devise their own
implementations of an apparatus, system, and method that incorporate one or
more of
the features of the present disclosure and fall within the spirit and scope of
the
invention as defined by the appended claims.
9
