Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/30—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by edge details of the ceiling; e.g. securing to an adjacent wall
  • E04B9/303—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by edge details of the ceiling; e.g. securing to an adjacent wall for flexible tensioned membranes
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
  • E04B2009/0492—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like with fabrics tensioned on frames
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/001—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by provisions for heat or sound insulation
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/06—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members
  • E04B9/065—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members comprising supporting beams having a folded cross-section
  • E04B9/067—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members comprising supporting beams having a folded cross-section with inverted T-shaped cross-section
  • E04B9/068—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members comprising supporting beams having a folded cross-section with inverted T-shaped cross-section with double web
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/06—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members
  • E04B9/12—Connections between non-parallel members of the supporting construction
  • E04B9/122—Connections between non-parallel members of the supporting construction one member passing through the other member, both members laying at least partly in the same plane
  • E04B9/125—Connections between non-parallel members of the supporting construction one member passing through the other member, both members laying at least partly in the same plane both members being continuous members
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/06—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by constructional features of the supporting construction, e.g. cross section or material of framework members
  • E04B9/12—Connections between non-parallel members of the supporting construction
  • E04B9/127—Connections between non-parallel members of the supporting construction one member being discontinuous and abutting against the other member
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
  • E04B9/34—Grid-like or open-work ceilings, e.g. lattice type box-like modules, acoustic baffles
  • E04B9/36—Grid-like or open-work ceilings, e.g. lattice type box-like modules, acoustic baffles consisting of parallel slats
  • E04B9/363—Grid-like or open-work ceilings, e.g. lattice type box-like modules, acoustic baffles consisting of parallel slats the principal plane of the slats being horizontal

Definitions

• the present invention generally relates to ceiling systems, and more particularly to suspended ceiling systems which create a seamless appearance.
• acoustic ceilings which are integrally formed with the top surface of a space sacrifice significant acoustic performance in favor of a very uniform and seamless visual appearance.
• acoustic ceilings formed of acoustic ceiling panels installed within a grid system are able to significantly increase the acoustic performance of the acoustic ceiling, but only at the sacrifice of a seamless visual appearance.
• Acoustic ceilings have therefore been introduced which hide the grid system, by concealing it within the edges of the supported acoustic celling panels, in order to present a more visually appealing appearance to the ceiling.
• an improved ceiling system is desirable, particularly one which is better able to decouple visual appearance from acoustic performance.
• the present invention provides a ceiling system which includes a ceiling structure suspended from an overhead structure, such that the ceiling structure provides a seamless visual appearance and offers the ability to fine tune the acoustic properties of the ceiling system without altering or affecting the overall visual appearance.
• the seamless visual appearance is achieved by stretching a single sheet of fabric across an entire ceiling structure, which may be formed of a frame, may include a grid of acoustic ceiling panels, and may be suspended from an overhead structure within a space free from direct attachment to walls or other similar ceiling structures.
• a ceiling system includes a ceiling structure suspended in an interior space.
• the ceiling structure includes: a perimeter frame defining a central opening, the perimeter frame comprising a fabric gripping member; a support grid comprising a plurality of intersecting struts defining a plurality of grid openings, the support grid disposed within the central opening and coupled to the perimeter frame; a plurality of acoustic ceiling panels, each of the acoustic ceiling panels mounted to the support grid and disposed in one of the grid openings; and a tensioned fabric sheet having a perimeter portion that is engaged by the fabric gripping member of the perimeter frame, the tensioned fabric sheet located below the acoustic ceiling panels and covering the central opening.
• a ceiling system including a ceiling structure suspended in an interior space.
• the ceiling structure includes: a perimeter frame defining a central opening, the perimeter frame including: a first fabric gripping member; and a second fabric gripping member; a first tensioned fabric sheet having a perimeter portion that is engaged by the first fabric gripping member of the perimeter frame, the first tensioned fabric sheet covering the central opening; and. a second tensioned fabric sheet having a perimeter portion that is engaged by the second fabric gripping member of the perimeter frame, the second tensioned fabric overlying the first tensioned fabric.
• a ceiling system including a ceiling structure suspended in an interior space.
• the ceiling structure includes a perimeter frame defining a central opening, the perimeter frame including: a fabric gripping member; a track comprising a first retaining element configured to couple the fabric gripping member to the track and a second retaining element configured to couple the fabric gripping member to the track; and the fabric gripping member coupled to a selected one of the first or second retaining elements; and a tensioned fabric sheet having a perimeter portion that is engaged by the fabric gripping member of the perimeter frame, the tensioned fabric covering the central opening.
• a fabric gripping apparatus includes: an anchor plate; a gripping portion including: a first wall extending outward from a first surface of the anchor plate; a second wall extending outward from the first surface of the anchor plate and extending substantially orthogonal to the anchor plate along a first reference plane, the second wall comprising a base section and a first gripping section having a plurality of first teeth; a fabric collection cavity formed between the first wall and the base section of the second wall; a gripping plate connected to a distal end of the first wall, the gripping plate comprising a lever section and a second gripping section having a plurality of second teeth; and the gripping plate positioned so that the second teeth oppose the first teeth to form an access slot into the fabric collection cavity, the gripping plate oriented so that the lever section of the gripping plate diverges from the first reference plane with distance from the anchor plate.
• FIG. 1 is a side cross-section view of a plurality of ceiling structures suspended in an interior space to form a ceiling system
• FIG. 2 is a bottom perspective view of a first ceiling structure and suspension members
• FIG. 3 is a top perspective view of the first ceiling structure and suspension members
• FIG. 4 is an exploded view of the first ceiling structure and suspension members
• FIG. 5A is a partial cross- sectional view of the first ceiling structure along the line VA— VA of FIG. 3;
• FIG. 5B is a detail view of section VB of FIG. 5A showing the fabric sheet engaged by the fabric gripping member
• FIG. 6 is a top perspective view of the perimeter frame and the support grid for the first ceiling structure of FIG. 3;
• FIG. 7 is a detail view of section VII of FIG. 6 showing coupled frame members
• FIG. 8 is a detail view of section VIII of FIG. 6 showing coupled intersecting struts of the support grid
• FIG. 9A is a detailed view of section IXA of FIG. 6 showing the strut of the support grid coupled to the frame member of the perimeter frame;
• FIG. 9B is an exploded view of a support bracket for a ceiling structure
• FIG. 10 is a detailed view of section X of FIG. 4 showing the end of a perimeter frame member and a fabric gripping member;
• FIG. 11 is a bottom perspective view of a second ceiling structure;
• FIG. 12 is a partial cross-sectional view of the second ceiling structure along the line XII— XII of FIG. 11;
• FIG. 13 is a bottom perspective view of a third ceiling structure.
• FIG. 14 is a partial cross-sectional view of the third ceiling structure along the line IV—
• 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 invention.
• Relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation.
• FIG. 1 illustrates a ceiling system 11 including a plurality of ceiling structures 13 installed within an interior space 15.
• Each ceiling structure 13 is suspended from an overhead structure 17 of the interior space 15 by a plurality of suspension members 19, such that each celling structure 13 is spaced apart from the overhead structure 17 and suspended in a free- hanging manner below the overhead structure 17.
• the overhead structure 17 may be a beam or other structural member of the interior space 15, and the suspension members 19 may be wires, cables, tie rods, hangers, struts, and the like.
• Each ceiling structure 13 is suspended from the overhead structure 17 of the interior space 15 without being directly affixed to any wall 21 of the interior space 15.
• Each ceiling structure 13 is also not directly affixed to any of the other ceiling structures 13.
• one or more ceiling structures 13 may be suspended within the interior space 15 solely by the suspension members 19. Although each of the ceiling structures 13 are shown as being parallel to the floor 23 of the interior space 15 and to each other, in certain embodiments one or more of the ceiling structures 13 may be suspended so that it is non-parallel to the floor 23 and/or non-parallel to one or more of the other ceiling structures 13.
• one or more of the celling structures 13 may be suspended within the interior space 15 so as to be partially or entirely spaced from all walls 21 of the interior space 15.
• any one or more of the ceiling structures 13 may be directly coupled to one or more of the walls or one of the other ceiling structures 13.
• the ceiling structure 13 is coupled to a wall or other ceiling structure 13
• directly coupling any one or more of the ceiling structures 13 to one or more of the walls or to one or more of the other ceiling structures 13 may be done to create differences in the overall visual appearance of the interior space 15.
• only one ceiling structure 13 may be included in an interior space, such that the one ceiling structure 13 spans from wall to wall of the interior space, thereby enabling uniform acoustic performance across the interior space, while at the same time allowing the presentation of a desired seamless visual appearance that is decoupled from the acoustic performance of the ceiling structure 13.
• the ceiling system 11 may include one or more ceiling structures 13 installed in a space which includes an overhead structure 17 and is not bounded by walls. Such an embodiment is possible because walls are not required to provide structural support to the ceiling structures 13 that form the ceiling system 11.
• FIG. 2 a bottom perspective view of a ceiling structure 13 is shown.
• the ceiling structure 13 includes a perimeter frame 31 forming a side periphery 33 of the ceiling structure 13 and a tensioned fabric sheet 35 coupled to the perimeter frame 31 to form a bottom face 37 of the ceiling structure 13.
• the tensioned fabric sheet 35 has a perimeter portion secured to the perimeter frame 31 along the entire periphery of the bottom face 37 of the ceiling structure 13 so that the tensioned fabric sheet 35 presents a seamless visual appearance. In the embodiment shown, only a small perimeter portion of the bottom face 37 is not covered by the tensioned fabric sheet 35.
• the side periphery 33 of the ceiling structure 13 remains exposed to view.
• the side periphery 33 of the ceiling structure 13 formed by the perimeter frame 31 is unbroken by holes or seams, with the exception of at the corners of the perimeter frame 31, so that the side periphery 33 also presents a seamless visual appearance.
• FIG. 3 A top perspective view of the ceiling structure 13 is shown in FIG. 3.
• the perimeter frame 31 forms a central opening 41, and a support grid 43 having a plurality of intersecting struts 45, forming a plurality of grid openings 47, is coupled to the perimeter frame 31 within the central opening 41.
• the manner in which the support grid 43 is coupled to the perimeter frame 31 is a matter of design choice, and is not to be limiting of the invention.
• a plurality of acoustic ceiling panels 49 are mounted to the support grid 43, with each acoustic ceiling panel 49 being disposed in one of the grid openings 47.
• the perimeter frame 31 is shown as being a square and the support grid 43 is shown as a rectangular grid.
• the perimeter frame 31 may be formed in other shapes, and similarly, the support grid may have other grid patterns, such as square, hexagonal, and the like.
• the tensioned fabric sheet 35 spans across the entire central opening 41 of the perimeter frame 31, the appearance of the acoustic ceiling panels 49 may be entirely irrelevant because they are blocked from view by the tensioned fabric sheet 35. Therefore the acoustic performance of the acoustic ceiling panels 49, in certain embodiments, may be improved because there is no need for the acoustic ceiling panels 49 to strike a balance between acoustic performance and aesthetic appearance.
• the support grid 43 in addition to supporting the acoustic ceiling panels 49, also serves as a support assembly for the ceiling structure 13.
• the suspension members 19 have a first end 51 coupled to the support grid 43 and a second end 53 that is configured to couple to the overhead structure 17 of the interior space 15.
• the acoustic ceiling panels 49 may be omitted, such that the support grid 43 may have a structure that need not be configured to support the acoustic ceiling panels 49.
• the support grid 43, as a support assembly need not be a grid at all, but rather configured purely as a support assembly for the ceiling structure 13.
• the perimeter frame 31 includes elongated frame members 61 and elongated grip bars 63 coupled to each elongated frame member 61.
• Each elongated frame member 61 is coupled to an adjacent elongated frame member 61 by corner brackets 65, so that when the elongated frame members 61 are all coupled together, the perimeter frame 31 having the central opening 41 is formed.
• the elongated frame members 61 With the elongated frame members 61 coupled to form the perimeter frame 31, the elongated frame members 61 collectively form a track 67 that circumscribes the central opening 41.
• the elongated grip bars 63 are coupled to the elongated frame members 61, so that they are also effectively coupled to the track 67, to circumscribe the central opening 41 and collectively form a fabric gripping member 69.
• the perimeter portion of the tensioned fabric sheet 35 is coupled to each of the elongated grip bars 63 so that the tensioned fabric sheet 35 is secured to the perimeter frame 31 along the entire periphery of the bottom face 37 of the ceiling structure 13, thereby covering the central opening 41.
• the elongated grip bars 63 serve to maintain the tensioned fabric sheet 35 in a tensioned state across the central opening 41.
• the ceiling structure 13 may include more than one fabric gripping member 69.
• the fabric gripping member 69 may be coupled to the track 67 in any desired location.
• the support grid 43 is formed from the plurality of intersecting struts 45, which include longitudinal strut members 71 (e.g. main beams) and lateral strut members 73 (e.g. cross tees).
• the longitudinal strut members 71 may be referred to as main beams because in certain embodiments the suspension members 19 may couple to these strut members alone to providing suspension support for the entire ceiling structure 13.
• the lateral strut members 73 may be referred to as cross tees because these strut members are generally, but not necessarily, supported only by the longitudinal strut members 71 without having suspension members 19 securing them to the overhead structure.
• the longitudinal and lateral strut members 71, 73 are elongated in shape having a length greater than their respective width (e.g. at least twice), and in various embodiments lengths substantially greater than their widths (e.g. 3 times or more).
• the longitudinal strut members 71 may have a substantially greater length than the lateral strut members 73, such that the longitudinal strut members 71 form "runners" or “rails" which are maintained in a substantially parallel spaced apart relationship by the lateral strut members 73.
• the lateral strut members 73 may be permanently or detachably coupled to and between adjacent (but spaced apart) longitudinal strut members 71 at appropriate intervals.
• the manner in which the lateral strut members 73 are coupled to the longitudinal strut members 71 is a matter of design choice, and is not to be limiting of the invention.
• the support grid 43 also includes support members 75 which couple to multiple ones of adjacent (but spaced apart) longitudinal strut members 71, and the first end 51 of the suspension members 19 may be coupled to the support members 75.
• the support members 75 may also be coupled to adjacent lateral strut members 73 to provide greater stability in the lateral direction.
• every longitudinal strut member 71 need not be directly coupled to one of the suspension members 19.
• the combination of the interconnected longitudinal and lateral strut members 71, 73 and the support members 75 helps provide strength and stability to the ceiling structure 13.
• the longitudinal and lateral strut members 71, 73 intersect to form an array of grid openings 47 which receive and are closed by ceiling panels 49 when positioned within the grid openings 47.
• the longitudinal and lateral strut members 71, 73 may be arranged in an orthogonal pattern to intersect, respectively, at right angles (i.e., perpendicular) to form grid openings 47 which are rectilinear, such as squares or rectangles (in top plan view).
• the terminal ends 81 of the lateral strut members 73 that couple to the longitudinal strut members 71 have end connections configured for permanent or detachable connection to the longitudinal strut members 71 at right angles as part of forming the rectilinear grid pattern.
• the lateral strut members 73 may be coupled to the longitudinal strut members 71 through use of a permanent connection such as, without limitation, welding, soldering, and the like, or through use of a detachable connection such as, without limitation, clips, brackets, threaded fasteners, interlocking tabs/slots, and the like. Accordingly, the present invention is not limited by the manner of attachment or coupling used between the lateral strut members 73 and the longitudinal strut members 71 unless otherwise so limited by the claims.
• the terminal ends 83 of the lateral strut members 73 that couple to the elongated frame members 61 have end connections configured for permanent or detachable connection to the elongated frame members 61 at right angles as part of forming the rectilinear grid pattern.
• the lateral strut members 73 may be coupled to the elongated frame members 61 through the use of a support bracket 85.
• the lateral strut members 73 may be coupled to the elongated frame members 61 through the use of any detachable connection such as, without limitation, clips, brackets, threaded fasteners, interlocking tabs/slots, and the like. Accordingly, the present invention is not limited by the manner of attachment or coupling used between the lateral strut members 73 and the elongated frame members 61 unless otherwise so limited by the claims.
• the terminal ends 87 of the longitudinal strut members 71 have end connections configured for permanent or detachable end-to-end connection to the elongated frame members 61 to form the continuous spans of the main beams.
• the longitudinal strut members 71 may likewise be coupled to the elongated frame members 61 through the use of the support bracket 85.
• the longitudinal strut members 71 may be coupled to the elongated frame members 61 through the use of any detachable connection such as, without limitation, clips, brackets, threaded fasteners, interlocking tabs/slots, and the like. Accordingly, the present invention is not limited by the manner of attachment or coupling used between the longitudinal strut members 71 and the elongated frame members 61 unless otherwise so limited by the claims.
• the configuration and orientation of the parts forming the support grid 43 may vary widely while still remaining within the scope of the claims.
• some lateral strut members 73 may be run the same direction between and parallel to main beam longitudinal strut members 71, the longitudinal strut members 71 and the lateral strut members 73 may intersect at non-perpendicular angles, any part or all of the support grid 43 may be positioned in a horizontal or other orientation. Any combination of such alternative design characteristics may be incorporated into the ceiling structure 13.
• the acoustic ceiling panels 49 may be of any appropriate design to provide the ceiling structure 13 desired acoustical properties.
• an exemplary acoustic ceiling panel 49 may include at least a core layer (not shown) (not shown) formed from one or more sub-layers.
• the acoustic ceiling panel 49 has a generally rectangular shape.
• the acoustic ceiling panel 49 may be square, have more or fewer peripheral sides, or be irregularly shaped.
• the core layer of such an exemplary acoustic ceiling panel 49 may be constructed of any suitable material or combinations of different materials, which in certain embodiments preferably have acoustical properties.
• core layer materials that may be used include, without limitation, mineral fiber board, fiberglass, metals, polymers, metal, wood, composites, combinations thereof, or other.
• Embodiments of the core layer may be constructed so that the acoustic ceiling panel 49 has a sufficiently high noise reduction coefficient (NRC) and ceiling attenuation class (CAC) rating to be characterized as an acoustical substrate in contrast to gypsum-based drywall having substantially lower NRCs (e.g. 0.05) characteristic of sound reflecting, not absorbing materials.
• NRC is a measure of sound energy absorption of a material.
• An NRC rating of 0 is a perfect sound reflection material.
• An NRC rating of 1 is a perfect sound absorption material.
• CAC is a measure for rating the performance of a ceiling material as a barrier to block airborne sound transmission through the material to/from the upper interior space above the suspended ceiling panels and into an adjacent room. This property is measured in decibels (dB).
• the core layer may impart to the acoustic ceiling panel 49 an NRC of at least 0.50 and/or CAC of at least 30 dB depending on the desired acoustical characteristics of the ceiling system.
• the NRC rating may be at least 0.70.
• additional acoustic layers and/or features may be included as part of the acoustic ceiling panel 49, along with the core layer, to achieve desired acoustic properties for the acoustic ceiling panel 49.
• Fig. 5 A shows a cross sectional view of the ceiling structure 13.
• Two opposing frame members 61 are each coupled to opposite ends of a longitudinal strut member 71.
• the profiles of the two frame members 61 show the track 67 that circumscribes the central opening 41 of the perimeter frame 31, and as shown, the track 67 is bilaterally symmetric. In certain embodiments, the track 67 may be partially symmetric, or not symmetric at all.
• the track 67 includes an upstanding wall 91 which has an outer surface 93 and an inner surface 95.
• the inner surface 95 includes a lower support element 97 and an upper support element 99.
• Each of the lower and upper support elements 97, 99 are configured to couple the support brackets 85 to the perimeter frame 31.
• the support brackets 85 are discussed in greater detail below.
• Each of the lower and upper support elements 97, 99 also permit the support brackets 85 to be coupled to the perimeter frame 41 at a first height (the lower support element 97) or at a second height (the upper support element 99), respectively.
• a lower retaining element 101 protrudes from the inner surface 95 of the upstanding wall 91 at a bottom portion of the upstanding wall 91, and an upper retaining element 103 protrudes from the inner surface 95 of the upstanding wall 91 at a top portion of the upstanding wall 91.
• each of the retaining elements 101, 103 circumscribes the central opening 41 of the perimeter frame 31. In certain embodiments, either one or both of the retaining elements 101, 103 may not circumscribe the central opening 41. In certain embodiments, one or the other of the retaining elements 101, 103 may be omitted.
• both retaining elements 101, 103 have identical configurations but different orientations, and as such the ensuing description applies to the configurations of both. Therefore, the description of the retaining element 101 applies equally to the retaining element 103, except for where otherwise noted. In certain embodiments, however, the retaining elements 101, 103 may have different configurations.
• the retaining element 101 includes a retaining channel 105 and an access slot 107 forming a passageway into the retaining channel 105.
• the access slot 107 of the lower retaining element 101 faces downward, and the access slot 107 of the upper retaining element 103 faces upward.
• the retaining element 101 also includes a floor 109, a first wall 111, and a second wall 113 that collectively define the retaining channel 105 and access slot 107, and at least one of the walls 111, 113 of the retaining element 101 includes an overhang portion 115.
• one of the elongated grip bars 63 may be placed in sliding relationship with the retaining element 101.
• the fabric gripping member may be coupled to one or the other of the retaining elements 101, 103. With elongated grip bars 63 coupled to the retaining members 101 of each frame member 61, the fabric gripping member 69 circumscribes the central opening 41.
• the elongated grip bar 63 protrudes from the inner surface 95 of the upstanding wall 91, from a location at a bottom portion of the upstanding wall 91, so that the outer surface 93 of the upstanding wall 91 remains exposed when the tensioned fabric sheet 35 is coupled to the fabric gripping member 69.
• the bottom portion of the upstanding wall 91 circumscribes the tensioned fabric sheet 35.
• the elongated grip bar 63 protrudes from the inner surface 95 of the upstanding wall 91, from a location at a top portion of the upstanding wall 91, so that the tensioned fabric sheet 35 wraps around and at least partially conceals the outer surface 93 of the upstanding wall 91.
• FIG. 5B A detailed cross-sectional view of one of the elongated grip bars 63 coupled to the one of the retaining members 101 is shown in FIG. 5B.
• the collection of elongated grip bars 63 forms the fabric gripping member 69, such that the fabric gripping member 69 circumscribes the central opening 41.
• the elongated grip bar 63 extends along a longitudinal axis LA, and in certain embodiments, the elongated grip bar 63 may be formed as a singular monolithic component. In certain embodiments, the elongated grip bar 63 may be integrally formed with the frame member 61.
• the frame member 61 may be formed from extruded aluminum, with the elongated grip bar 63 extruded as an integral part of the frame member 61.
• the extruded frame members 61 may include multiple elongated grip bars 63, with each being formed integrally with the lower and upper retaining elements 101, 103, respectively.
• the elongated grip bar 63 is configured with a fabric collection cavity 121, a first gripping jaw 123, and a second gripping jaw 125.
• the first and second gripping jaws 123, 125 oppose one another to form an access slot 127, which forms a passageway into into the fabric collection cavity 121.
• the fabric gripping member 69 includes an anchor plate 131 and a gripping portion 133 in the form of the first and second gripping jaws 123, 125.
• the gripping portion 133 includes a first wall 135 and a second wall 137, both extending outward from a first surface 139 of the anchor plate 131.
• a gripping plate 141 which includes a lever section 143 and a second gripping section 145 having a plurality of first teeth 147, is connected to the distal end of the first wall 135.
• the first wall 135 may be a curved wall.
• the second wall 137 extends substantially orthogonal from the anchor plate 131 along a reference plane RP and includes a base section 151 and a gripper section 153 having a plurality of second teeth 155.
• the gripping plate 141 of the second wall 137 is positioned so that the plurality of first teeth 147 on the gripping plate 141 oppose the plurality of second teeth 155 of the gripper section 153.
• the first and second gripping jaws 123, 125 and the access slot 127 are formed, and the fabric collection cavity 121 is formed between the first wall 135 and the base section 151 of the second wall 153.
• the gripping plate 141 of the second wall 137 is oriented so that the lever section 143 diverges from the first reference plane RP the further the lever section 143 extends from the anchor plate 131.
• at least one of the first wall 135 or the second wall 137 is resilient, with the first and second teeth 147, 155 are biased into contact with one another. Having such a configuration, the first and second teeth 147, 155 may be drawn apart when an appropriate force is applied to the lever section 143 of the gripping plate 141.
• the perimeter portion of the tensioned fabric sheet 35 may be inserted into the fabric collection cavity 121 of the elongated grip bar 63 so that the first and second teeth 147, 155 of the first and second gripping jaws 123, 125 engage the perimeter portion of the tensioned fabric sheet 35 to hold the tensioned fabric sheet 35 in place.
• the tensioned fabric sheet 35 is therefore prevented from being withdrawn from the fabric collection cavity 121 by the first and second teeth 147, 155, which are biased toward each other.
• FIG. 6 shows a perspective view of the perimeter frame 31 forming the central opening 41, with the support grid 43 disposed within the central opening 41 and coupled to the perimeter frame 31.
• adjacent elongated frame members 61 are coupled together by two corner brackets 65.
• Each corner bracket 65 is seated within one of lower support element 97 and the upper support element 99, both of which are formed on the inner surface 95 of the track 67 formed by the perimeter frame 31.
• both lower and upper support elements 97, 99 have identical configurations, and as such the ensuing description applies to the configurations of both. Therefore, the description of the upper support element 99 applies equally to the lower support element 97, except for where otherwise noted.
• the lower and upper support elements 97, 99 may have different configurations.
• the upper support element 99 includes a first channel 161, a second channel 163, and a back wall 165, with the first channel 161 and the second channel 163 facing one another and the back wall 165 separating the first and second channels 161, 163.
• the back wall 165 includes a surface texturing 167, which may be a plurality of ridges, as depicted, or any other type of texturing that provides a fine-scale non- planar surface for the back wall 165.
• a first corner bracket 65 is inserted into the upper support element 99 with upper and lower edges of the corner bracket 65 seated, respectively, within the first channel 161 and the second channel 163 of the upper support element 99.
• a second corner bracket 65 is inserted into the lower support element 97 with upper and lower edges of the corner bracket 65 seated, respectively, within the first channel 161 and the second channel 163 of the lower support element 97.
• Each corner bracket 65 includes a threaded hole (not shown) into which a threaded fastener 169 is inserted, and each threaded fastener 169 engages the threaded hole so that an end of the threaded fastener 169 presses into the texturing 167 of the back wall 165.
• the surface texturing 167 of the back wall 165 serves to help maintain the threaded fastener 169 in place without slipping.
• the pressure of the threaded fastener 169 against the back wall 165 causes the upper and lower edges of the corner bracket 65 to press against the walls of the respective first and second channels 161, 163.
• the combination of the pressure of the threaded fastener 169 against the back wall 165 and the pressure of the corner bracket 65 against the walls of the first and second channels 161, 163 serves to hold the corner bracket 65 in position with respect to the frame member 31, which in turn serves to secure and hold adjacent frame members 31 together.
• FIG. 8 One intersection 181 of the intersecting struts 45 is shown in FIG. 8.
• Two lateral strut members 73 are shown coupled to the longitudinal strut member 71.
• the terminal ends 81 of the lateral strut members 73 each include a coupling extension 183 which engages a coupling slot 185 (also seen in FIG. 9A) formed in the sidewall of the longitudinal strut member 71.
• the top section 187 of the longitudinal strut member 71 includes a rail 189 which is larger than the middle section 191, and the rail 189 includes downward-facing edges 193 (seen in FIG. 9A).
• the support member 75 includes a slot 193 which has a shape that is complementary to the shape the rail 189, and slot 193 includes flanges 195 which extend under the downward-facing edges 193 of the rail 189. Holes 197 are included in the support member 75 for attachment to the suspension members 19 (see, e.g., FIG. 3).
• the support member 75 may also be directly coupled to the lateral strut members 73 by a fastener, such as a screw, clip, or other appropriate fastener.
• the support member 75 may be placed on the longitudinal strut member 71 with the rail 187 extending through the slot 193, and with the support member 75 coupled to adjacent longitudinal strut members 71 in this same manner. In this manner, the support member 75 may be used to suspend the support grid 43, and thus the entire ceiling structure 13, by attachment of the suspension members 19 to the support members 75.
• FIG. 9A The coupling of a longitudinal strut member 71 to a frame member 61 is shown in FIG. 9A.
• a lateral strut member 73 may be coupled to a frame member 61 in the same manner.
• the terminal end 87 of the longitudinal strut member 71 is coupled to the lower support element 97 of the track 67 by the support bracket 85.
• the longitudinal strut member 71 may alternatively be coupled to the upper support element 99 of the track 67 by the support bracket 85.
• the support bracket 85 is secured to the longitudinal strut member 71 by fasteners 201 and to the lower support element 97 of the track 67 by a threaded fastener 203.
• the fasteners 201 are shown as screws, although in other embodiments, the fasteners may be clips or any other type of appropriate fastener.
• the support bracket 85 which is shown in FIG. 9B, includes an "L” bracket member 211 and a clamp member 213.
• the "L” bracket member 211 includes a first leg 215 with holes 217 for securing the "L" bracket member 211 to the longitudinal strut member 71 (or to a lateral strut member 73) and a second leg 219 with a hole 221 through which the threaded fastener 203 passes.
• the second leg 219 of the "L" bracket member 211 includes a middle planar portion 223, with the first leg extending from a first side of the middle planar portion 223.
• the second leg 219 also includes a bottom portion 225 which extends at an acute angle from a second side of the middle planar portion 223, the second side of the middle planar portion 223 being opposite the first side.
• the second leg 219 also includes a top portion 227 which extends at an acute angle from the second side of the middle planar portion 223 in the opposite direction of the first leg 215.
• the top portion 227 also includes an engagement leg 229, which is substantially parallel to the middle planar portion 223 and positioned to engage one of the first and second channels 161, 163 of one of the lower and upper support elements 97, 99.
• the clamp member 213 includes a middle planar portion 231 with a threaded hole 233 for engaging the threaded fastener 203.
• a first side of the middle planar portion 231 faces the "L" bracket member 211 when the two are secured together.
• One end of the middle planar portion 231 includes a stabilizing tab 235 extending from the first side of the clamp member 213, and the stabilizing tab 235 serves to help prevent the clamp member 213 and the "L" bracket member 211 from rotating with respect to each other when coupled together by the threaded fastener 203.
• the bottom portion 237 of the clamp member 213 extends at an acute angle from the second side of the clamp member 213 in the opposite direction of the stabilizing tab 235.
• the bottom portion 237 also includes an engagement leg 239, which is substantially parallel to the middle planar portion 231 and positioned to engage the one of the first and second channels 161, 163 of one of the lower and upper support elements 97, 99.
• the support bracket 85 secures to one of the lower and upper support elements 97, 99 with the engagement leg 229 of the "L" bracket member 211 positioned in one of the first and second channels 161, 163 and the engagement leg 239 of the clamp member 213 positioned in the other of the first and second channels 161, 163.
• the bottom portion 225 of the "L" bracket member 211 is located outside of the one of the first and second channels 161, 163 in which the engagement leg 239 of the clamp member 213 is positioned.
• the clamp member 213 When the threaded fastener 203 engages the threaded hole 233 of the clamp member 213, the clamp member 213 is drawn toward the "L" bracket member 211, and the threaded fastener 203 presses into the texturing 167 of the back wall 165 of the respective lower and upper support element 97, 99.
• the texturing 167 of the back wall 165 serves to help maintain the threaded fastener 203 in place without slipping.
• the pressure of the threaded fastener 203 against the back wall 165 causes the engagement leg 229 of the "L" bracket member 211 and the engagement leg 239 of the clamp member 213 to press against the walls of the respective first and second channels 161, 163.
• the support bracket 85 serves to securely couple a longitudinal strut member 71 (or a lateral strut member 73) to the track 67.
• the outer surface of the upstanding wall 91 may be formed without any through holes.
• FIG. 10 The end of a frame member 61, including the elongated grip bar 63, is shown in FIG. 10. As illustrated, the end 251 of the frame member 61, including the end 253 of the elongated grip bar 63 are mitered at approximately a 45° angle so that four frame members 61 may be assembled together to form a square or rectangular perimeter frame 31 having a central opening 41. In certain embodiments, the frame members 61 may have ends mitered at angles other than 45° so that the resulting perimeter frame 31 has a shape other than square or rectangular. In certain other embodiments, different frame members 61 may have ends mitered at different angles so that the resulting perimeter frame 31 may have an irregular polygonal shape.
• FIG. 11 shows a bottom perspective view of an alternative embodiment for a ceiling structure 301.
• This ceiling structure 301 is has the same essential structure described above with respect to the ceiling structure 13 of FIG. 2, with the exception that the tensioned fabric sheet 303 is coupled to the perimeter frame 307 in a manner so as to wrap around the outer surface of the perimeter frame 307.
• the cross-sectional view of the ceiling structure 301 shown in FIG. 12 illustrates this difference.
• Two opposing frame members 311 are each coupled to a longitudinal strut member 313.
• the profiles of the two frame members 311 show the track 315 that circumscribes the central opening formed by the perimeter frame 307, and as shown, the track 315 is bilaterally symmetric. In certain embodiments, the track 315 may be partially symmetric, or not symmetric at all.
• the track 315 includes an upstanding wall 321 which has an outer surface 323 and an inner surface 325.
• the inner surface 325 includes a lower support element 327 and an upper support element 329.
• Each of the lower and upper support elements 327, 329 are configured to couple the support brackets 331 to the perimeter frame 307.
• Each of the lower and upper support elements 327, 329 also permit the support brackets 331 to be coupled to the perimeter frame 307 at a first height (the lower support element 327) or at a second height (the upper support element 329), respectively.
• the support brackets 331 have the same configuration as the support bracket 85 shown in FIG. 9B.
• a lower retaining element 335 protrudes from the inner surface 325 of the upstanding wall 321 at a bottom portion of the upstanding wall 321, and an upper retaining element 337 protrudes from the inner surface 325 of the upstanding wall 321 at a top portion of the upstanding wall 321.
• each of the retaining elements 335, 337 circumscribes the central opening of the perimeter frame 307. In certain embodiments, either one or both of the retaining elements 335, 337 may not circumscribed the central opening. In certain embodiments, the lower retaining element 101 may be omitted.
• One of the elongated grip bars 341 is placed in sliding relationship with the retaining element 337, and with elongated grip bars 341 so placed with each frame member 311, a fabric gripping member is formed that circumscribes the central opening of the perimeter frame 307.
• the elongated grip bar 341 of this embodiment may be formed the same as the elongated grip bar 63 shown in FIG. 5B.
• FIG. 13 shows a bottom perspective view of an alternative embodiment for a ceiling structure 401.
• This ceiling structure 401 has the same essential structure described above with respect to the ceiling structure 13 of FIG. 2, with the exception that the ceiling structure 401 includes two tensioned fabric sheets 403, 405 (the first tensioned fabric sheet 403 is shown in FIG. 14) coupled to the perimeter frame 407 in a manner so that the second tensioned fabric sheets 405 wraps around the outer surface of the perimeter frame 407.
• the cross-sectional view of the ceiling structure 401 shown in FIG. 14 illustrates this difference.
• Two opposing frame members 411 are each coupled to a longitudinal strut member 413.
• the profiles of the two frame members 411 show the track 415 that circumscribes the central opening formed by the perimeter frame 407, and as shown, the track 415 is bilaterally symmetric. In certain embodiments, the track 415 may be partially symmetric, or not symmetric at all.
• the track 415 includes an upstanding wall 421 which has an outer surface 423 and an inner surface 425.
• the inner surface 425 includes a lower support element 427 and an upper support element 429.
• Each of the lower and upper support elements 427, 429 are configured to couple the support brackets 431 to the perimeter frame 407.
• Each of the lower and upper support elements 427, 429 also permit the support brackets 431 to be coupled to the perimeter frame 407 at a first height (the lower support element 427) or at a second height (the upper support element 429), respectively.
• the support brackets 431 have the same configuration as the support bracket 85 shown in FIG. 9B.
• a lower retaining element 435 protrudes from the inner surface 425 of the upstanding wall 421 at a bottom portion of the upstanding wall 421, and an upper retaining element 437 protrudes from the inner surface 425 of the upstanding wall 421 at a top portion of the upstanding wall 421.
• each of the retaining elements 435, 437 circumscribes the central opening of the perimeter frame 407.
• One of the elongated grip bars 441 is placed in sliding relationship with the retaining element 435, and another of the elongated grip bars 443 is placed in sliding relationship with the retaining element 437.
• Each elongated grip bar 441, 435 of this may be formed the same as the elongated grip bar 63 shown in FIG. 5B.
• two fabric gripping members are formed that circumscribes the central opening of the perimeter frame 407.
• the first tensioned fabric sheet 403 is engaged by the grip bars 441 of the first fabric gripping member, in the manner described above, to tension the first tensioned fabric sheet 403 across the central opening of the perimeter frame 407.
• the second tensioned fabric sheet 405 is engaged by the grip bars 443 of the second fabric gripping member, in the manner described above, to tension the second tensioned fabric sheet 405 across the central opening of the perimeter frame 407 and to wrap the second tensioned fabric sheet 405 around the outer surface of upstanding wall 421 of the perimeter frame 407 to conceal the outer surface of upstanding wall 421.
• the first tensioned fabric sheet 403 may be a first color and the second tensioned fabric sheet 405 may be a second color that is different than the first color.
• the first tensioned fabric sheet 403 may include a loose weaving or even larger holes which allow more of the second tensioned fabric sheet 405 to be seen underneath the first tensioned fabric sheet 403.

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• 2016
  • 2016-11-04 EP EP16864799.8A patent/EP3371388B1/de active Active
  • 2016-11-04 WO PCT/US2016/060438 patent/WO2017083181A1/en active Application Filing
  • 2016-11-04 CA CA3003279A patent/CA3003279C/en active Active

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