A modular ceiling system and construction method thereof

Abstract

The present invention provides a modular ceiling system and a construction method thereof, wherein the modular ceiling system comprises a plurality of ceiling modules, a hanger fixed on the top of a building, and a main keel fixedly connected to the bottom end of the hanger, wherein the ceiling modules are connected to the main keel, and there is no connection between adjacent ceiling modules; the ceiling module comprises a gypsum board with a finishing layer and at least two covering keels arranged parallel to each other on the non-decorative surface of the gypsum board, wherein the covering keel is clipped with the card-type keel; wherein the four sides of the gypsum board are bent toward the non-decorative surface of the gypsum board at a preset height, and the adjacent ends of the four sides of the gypsum board are fixedly connected by an adhesive. The modular ceiling system of the present invention is simple to construct and easy to install, and no decorative or connecting structures such as keels or buckle strips are required between adjacent ceiling modules, which greatly simplifies the structure of the ceiling system.

Description

Technical Field

[0001] The invention relates to the technical field of building decoration, and in particular to a modular ceiling system and a construction method thereof. Background Art

[0002] The ceiling system is an indispensable building structure in building decoration projects. Usually, the ceiling system has functions such as thermal insulation, heat insulation, sound insulation, and decoration to make up for the defects of the building itself and increase the sense of layering of the space. It is also an important structure for shielding electrical, ventilation and air-conditioning, communication, and fire protection spaces.

[0003] The existing gypsum board ceiling systems are all spliced ​​ceiling systems, that is, adjacent gypsum boards are connected by structures such as keels or buckles. The structure of the ceiling system is complex and the construction operation is cumbersome. It is often necessary to arrange and install edge banding keels or buckles and other connecting and decorative structural parts before installing the gypsum board, and then install the gypsum board, which makes the gypsum board easy to be damaged or even destroyed during the installation process, especially the gypsum board module with grooved edges. Due to the grooved setting, its edges are weaker and it is very easy to be damaged and scrapped, which increases construction waste and construction costs. Summary of the invention

[0004] The present invention aims to solve the problems described above. One object of the present invention is to provide a modular ceiling system and a construction method thereof that solves any of the above problems. Specifically, the present invention provides a modular ceiling system and a construction method thereof that can be installed easily without the need for connecting structures such as decorative buckle strips or edge banding keels.

[0005] According to a first aspect of the present invention, the present invention provides a modular ceiling system, which comprises a plurality of ceiling modules, a hanger fixed to the top of a building, and a main keel fixedly connected to the bottom end of the hanger, wherein the ceiling modules are connected to the main keel, and there is no connection between adjacent ceiling modules; the ceiling module comprises a gypsum board with a finishing layer and at least two covering keels arranged parallel to each other on the non-decorative surface of the gypsum board, and the covering keels are clipped with the card-type keels; wherein the four sides of the gypsum board are bent at a preset height toward the non-decorative surface of the gypsum board, and the adjacent ends of the four sides of the gypsum board are fixedly connected by an adhesive.

[0006] Wherein, the gypsum board is provided with V-shaped back grooves at the bending positions of the four sides thereof, and the depth of the V-shaped back grooves is less than the thickness of the gypsum board.

[0007] In the embodiment, the preset height is less than or equal to the thickness of the covering keel.

[0008] In one embodiment, the ceiling module further includes an adhesive layer, and the adhesive layer is located between the gypsum board and the covering keel.

[0009] Wherein, the ceiling module also includes a reinforcement layer and several reinforcement pieces, the reinforcement layer is located between the gypsum board and the covering keel, the reinforcement layer and the gypsum board are fixedly connected by an adhesive layer, and the reinforcement layer and the covering keel are fixedly connected by the reinforcement pieces.

[0010] Wherein, the reinforcement layer comprises gypsum board strips and / or paper-faced gypsum board.

[0011] Wherein, the covering keel is a cassette keel.

[0012] Wherein, the modular ceiling system further comprises a plurality of clips arranged at intervals on the main keel, and the covering keel is connected to the clips.

[0013] According to another aspect of the present invention, the present invention further provides a construction method of the modular ceiling system as described above, the construction method comprising the following steps:

[0014] Bend the four sides of the gypsum board to a preset height toward the opposite side of the decorative surface of the gypsum board, and fix the adjacent ends of the four sides of the gypsum board with an adhesive;

[0015] Fixing at least two mutually parallel covering keels on the opposite sides of the decorative surface of the gypsum board;

[0016] Installing the suspension rod at a predetermined position on the top of the building, and fixedly connecting the main keel to the suspension rod in a predetermined direction;

[0017] The facing keels on the gypsum board are connected to the corresponding preset positions of the main keels.

[0018] Wherein, the step of bending the four edges of the gypsum board to a preset height toward the opposite sides of the decorative surface of the gypsum board comprises:

[0019] A V-shaped back groove is opened on the opposite side of the decorative surface of the gypsum board at a preset distance from the edge, and the corner excess material formed by the intersection of adjacent V-shaped back grooves is removed, and then the edge of the gypsum board is bent along the V-shaped back groove toward the non-decorative surface of the gypsum board.

[0020] The modular ceiling system of the present invention is simple to construct and easy to install. The edge of the ceiling module is a bent structure of a gypsum board, which can decorate the ceiling module, i.e., the modular ceiling system, and improve the aesthetics of the modular ceiling system. No decorative or connecting structures such as keels or buckle strips are required between adjacent ceiling modules, which greatly simplifies the structure of the ceiling system. At the same time, the covering keel on the back of the ceiling module can be directly connected to the clips on the main keel set on the top of the building, further simplifying the construction process of the ceiling system, shortening the construction period, and improving construction efficiency.

[0021] Other characteristic features and advantages of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The accompanying drawings, which are incorporated into the specification and constitute a part of the specification, illustrate embodiments of the present invention and are used together with the description to explain the principles of the present invention. In these drawings, similar reference numerals are used to represent similar elements. The drawings described below are some embodiments of the present invention, but not all embodiments. For those of ordinary skill in the art, other drawings can be obtained from these drawings without paying creative work.

[0023] Figure 1 A structural schematic diagram of a modular ceiling system of the present invention is exemplarily shown;

[0024] Figure 2 A structural schematic diagram of a ceiling module is exemplarily shown;

[0025] Figure 3 A second structural schematic diagram of a ceiling module is exemplarily shown;

[0026] Figure 4 A third structural schematic diagram of a ceiling module is exemplarily shown;

[0027] Figure 5 Another structural schematic diagram of the modular ceiling system of the present invention is exemplarily shown;

[0028] Figure 6 The flowchart of the construction method of the modular ceiling system of the present invention is exemplarily shown. DETAILED DESCRIPTION

[0029] In order to make the purpose, technical scheme and advantages of the embodiments of the present invention clearer, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. It should be noted that the embodiments in this application and the features in the embodiments can be combined with each other arbitrarily without conflict.

[0030] The inventor uses the facing gypsum board as the ceiling board material of the ceiling module, and then bends the four sides of the gypsum board to a preset height toward the opposite side of the decorative surface of the gypsum board, so as to cover the connection structure or installation structure such as the covering keel set on the opposite side of the decorative surface of the gypsum board, effectively beautifying the appearance of the suspended ceiling module, thereby beautifying the appearance of the suspended ceiling system. At the same time, there is no need to set a connection structure or decorative structure such as a keel or buckle strip between adjacent ceiling modules, which greatly simplifies the structure of the ceiling system. By setting at least two mutually parallel covering keels on the non-decorative surface of the gypsum board, it is only necessary to connect the covering keels to the main keels or clips set on the top of the building, which effectively reduces the construction difficulty of the ceiling system.

[0031] The modular ceiling system and the construction method thereof provided according to the present invention are described in detail below with reference to the accompanying drawings.

[0032] Figure 1 A schematic diagram showing a specific embodiment of the modular ceiling system of the present invention is shown. Figure 1 As shown, the modular ceiling system includes a plurality of ceiling modules 1, a hanger 2 fixed to the top of the building, and a main keel 3 fixedly connected to the bottom end of the hanger 2. The ceiling modules 1 are connected to the main keel 3, and there is no connection between adjacent ceiling modules 1, that is, there is no need to set connection structures or decorative structures such as edge banding keels or buckle strips or frame keels, which greatly simplifies the structure and construction process of the ceiling system.

[0033] Figure 2 A schematic diagram of the structure of a specific embodiment of the ceiling module 1 is shown. Figure 1 As shown, the ceiling module 1 includes a gypsum board 11 with a finishing layer and at least two covering keels 12 arranged parallel to each other on the non-decorative surface of the gypsum board 11 (i.e., the opposite surface of the decorative surface of the gypsum board 11). The gypsum board 11 is used as a finishing board material of the suspended ceiling module 1, and the covering keel 12 is connected to the clamp 4 to realize the installation of the ceiling module 1.

[0034] Among them, the four sides of the gypsum board 11 are bent to a preset height toward the non-decorative surface of the gypsum board 11 (i.e., the surface opposite to the decorative surface of the gypsum board 11), so that the gypsum board 11 forms a box-type structure without a cover, and the bent edges of the gypsum board 11 can cover the structures such as the covering keel 12 set on its non-decorative surface, effectively beautifying the appearance of the ceiling module 1, so as to ensure that after the construction of the modular ceiling system is completed, standing under the modular ceiling system will not affect the aesthetics of the suspended ceiling system due to the exposure of the covering keel 12 and other structures. Specifically, adjacent ceiling modules 1 can be arranged in contact with each other or arranged at intervals.

[0035] Furthermore, in order to ensure the stability of the shape of the gypsum board 11 after the edge is bent, the adjacent ends of the four edges of the gypsum board 11 are fixedly connected by an adhesive, thereby ensuring the shape stability of the ceiling module 1.

[0036] In order to prevent gaps from appearing on the edge of the ceiling module 1 or pattern deviations of the decorative layer, the ceiling module 1 of this solution uses the method of bending the four edges of the gypsum board 11 at a preset height, rather than using other gypsum board strips to connect the edges of the gypsum board 11. Specifically, since the gypsum board 11 is a hard material product with a certain thickness, in order to facilitate the bending of the edges of the gypsum board 11, V-shaped back grooves are provided at the bending positions of the four edges on the non-decorative surface of the gypsum board 11, and the depth of the V-shaped back groove is less than the thickness of the gypsum board 11, so as to prevent the decorative layer of the gypsum board 11 from being penetrated and affecting the appearance of the ceiling module 1. If, as in the present embodiment, the gypsum board 11 is bent to form a structure in which the bent edge is perpendicular to the decorative surface of the gypsum board 11, the angle of the V-shaped back groove is 90 degrees. The edge bending angle of the gypsum board 11 of the ceiling module 1 can also be designed to be an acute angle or an obtuse angle according to the actual shape of the suspended ceiling system, that is, the angle between the bent edge of the gypsum board 11 and the decorative surface of the gypsum board 11 is an acute angle or an obtuse angle, and the corresponding V-shaped back groove is set to an obtuse angle or an acute angle.

[0037] Furthermore, in order to fully realize the shielding effect after the edge of the gypsum board 11 is bent, and not hinder the connection between the covering keel 12 and the main keel 3, that is, the covering keel 12 will not interfere with the main keel 3 after installation, the preset height of the four edges of the gypsum board 11 needs to be less than or equal to the thickness of the covering keel 12. In this embodiment, that is, when the web of the covering keel 12 is connected to the gypsum board 11, the bending height of the four edges of the gypsum board 11 is less than the flange height of the covering keel 12.

[0038] In this solution, the ceiling module 1 further includes an adhesive layer 13, which is located between the gypsum board 11 and the facing keel 12, and the facing keel 12 is fixedly installed on the gypsum board 11 through the adhesive layer 13. For example, the adhesive layer 13 can be made of an adhesive such as gypsum adhesive or 3M glue that can achieve a fixed connection between the facing keel 12 and the gypsum board 11. At this time, the preset height of the four edges of the gypsum board 11 should be less than the sum of the thickness of the adhesive layer 13 and the thickness of the facing keel 12, so as to ensure that the connection between the facing keel 12 and the clamp 4 is not hindered.

[0039] Figure 3 FIG. 1 shows a structural schematic diagram of another specific embodiment of the ceiling module 1. Figure 4 The structural diagram of the third specific embodiment of the ceiling module 1 is shown. Figure 3 and Figure 4 As shown, the ceiling module 1 also includes a reinforcement layer 14 and a plurality of reinforcement members 15. The reinforcement layer 14 is located between the gypsum board 11 and the facing keel 12, and is used to reinforce the connection strength and stability between the facing keel 12 and the gypsum board 11. At the same time, the reinforcement layer 14 and the gypsum board 11, and the reinforcement layer 14 and the facing keel 12 are more easily connected. Without damaging the decorative layer of the gypsum board 11, it is easier to connect the facing keel 12 and the gypsum board 11 together. Specifically, the reinforcement layer 14 and the gypsum board 11 are fixedly connected by the adhesive layer 13, and the reinforcement layer 14 and the facing keel 12 are fixedly connected by the reinforcement member 15. Exemplarily, the reinforcement member 15 can be a countersunk screw, such as a flat head self-tapping screw.

[0040] The reinforcement layer 14 may be made of gypsum board strips or ordinary gypsum board. Figure 3 In the embodiment shown, the reinforcement layer 14 is a common paper-faced gypsum board having the same shape as the gypsum board 11 and a smaller outer dimension than the gypsum board 11 after being bent; Figure 4 In the illustrated embodiment, the reinforcement layer 14 is a gypsum board strip having a width slightly greater than the web width of the facing keel 12 .

[0041] In order to facilitate installation and simplify the installation process of the ceiling module 1, a plurality of buckles 31 can be arranged at equal intervals on the main keel 3, so that the covering keel 12 can be directly connected to the main keel 3 through the buckles 31. Among them, the covering keel 12 can be a card-type keel, or a U-shaped keel with an inner hanging groove that can be snapped with the buckle 31, so that the covering keel 12 can be directly connected to the card-type keel 3 through the buckles 31 at the corresponding position to complete the installation of the ceiling module 1.

[0042] Figure 5A structural schematic diagram of another specific embodiment of the modular ceiling system of the present invention is shown. In this embodiment, the modular ceiling system also includes a plurality of clips 4 spaced apart on the main keel 3, and the covering keel 12 is connected to the clips 4 at corresponding positions on the main keel 3 to complete the installation of the ceiling module 1.

[0043] Adapting to the above-mentioned modular ceiling system, the present invention also provides a construction method of the modular ceiling system. Figure 6 A flowchart showing the construction method is shown in FIG. Figure 6 As shown, the construction method specifically includes the following steps:

[0044] Step S1: bend the four sides of the gypsum board 11 to a preset height toward the opposite side of the decorative surface of the gypsum board 11, and fix the adjacent ends of the four sides of the gypsum board 11 with an adhesive;

[0045] Step S2: fixing at least two mutually parallel covering keels 12 on the opposite sides of the decorative surface of the gypsum board 11;

[0046] Step S3: installing the suspension rod 2 at a predetermined position on the top of the building, and fixing the main keel 3 to the suspension rod 2 in a predetermined direction;

[0047] Step S4: Connect the facing keel 12 on the gypsum board 11 to the corresponding preset position of the main keel 3 .

[0048] The above steps are steps for installing a ceiling module 1. According to the above steps, a plurality of ceiling modules 1 are installed one by one according to a predetermined rule to form a modular ceiling system of a predetermined shape.

[0049] Specifically, the step S1 of bending the four edges of the gypsum board 11 to a preset height toward the opposite side of the decorative surface of the gypsum board 11 includes: opening a V-shaped back groove on the opposite side of the decorative surface of the gypsum board 11 (i.e., the non-decorative surface of the gypsum board 11) at a preset distance from the edge (or on the opposite side of the decorative surface of the gypsum board 11, at a position relative to the molding size of the ceiling module 1), removing the excess material at the corners formed by the intersection of adjacent V-shaped back grooves, and then bending the four edges of the gypsum board 11 toward the non-decorative surface of the gypsum board 11 one by one along the V-shaped back groove.

[0050] Step S2 specifically includes: coating an adhesive layer 13 on the non-decorative surface of the gypsum board 11 and at the location where the facing keel 12 is to be installed. The adhesive layer 13 may be 3M glue of a predetermined thickness and a predetermined width, or may be gypsum adhesive lumps of a predetermined size distributed at intervals; and then fixing the web of the facing keel 12 to the gypsum board 11 through the adhesive layer 13 to form a ceiling module 1.

[0051] In another specific embodiment, when a reinforcement layer 14 (which may be a gypsum board strip or an ordinary paper-faced gypsum board) is further provided between the covering keel 12 and the gypsum board 11, step S2 specifically includes:

[0052] Step S21: The reinforcement layer 14 is fixedly connected to the covering keel 12 via the reinforcement member 15;

[0053] Step S22: applying an adhesive layer 13 at predetermined positions on the non-decorative surface of the gypsum board 11 at predetermined intervals, which may be 3M glue or gypsum adhesive;

[0054] Step S23 : fixing the reinforcement layer 14 with the covering keel 12 fixed thereto on the gypsum board 11 through the adhesive layer 13 to form the ceiling module 1 .

[0055] In an embodiment where the ceiling module 1 is connected to the main keel 3 via a clamp 4, step S3 further includes: arranging the clamp 4 at a predetermined position on the main keel 3. Accordingly, step S4 specifically includes: clamping the cladding keel 12 in the ceiling module 1 with the clamp 4 at a corresponding position on the main keel 3.

[0056] The specific construction process of a modular ceiling system of the present invention in actual operation can be carried out according to the following steps:

[0057] Step S11: a 90-degree V-shaped back groove is opened on the non-decorative surface of the gypsum board 11 with a finishing layer at a distance of 50 mm from the four sides, and the excess materials at the four corners formed by the intersection of the four V-shaped back grooves at the ends are removed, and then the four sides of the gypsum board 11 are respectively bent along the corresponding V-shaped back grooves toward the non-decorative surface of the gypsum board 11, and the ends of the adjacent sides are fixed by an adhesive to form a rectangular box-shaped structure without a cover;

[0058] Step S21: Process a C-shaped keel with a length less than or equal to the length of the V-shaped back groove as the covering keel 12, process a gypsum board strip with a width of 100 mm and a thickness of 12 mm as the reinforcement layer 14, and the length of the reinforcement layer 14 is consistent with the length of the covering keel 12, and fix the gypsum board strip to the web of the covering keel 12 by self-tapping screws;

[0059] Step S22: applying adhesive plaster or 3M glue on the non-decorative surface of the gypsum board 11, bonding and fixing the gypsum strips to the gypsum board 11 through the plaster or 3M glue, and waiting for the plaster or 3M glue to completely solidify, so as to form the ceiling module 1; wherein, plaster or 3M glue can also be applied to the inner walls around the gypsum board 11 after bending, and the side surfaces of the covering keel 12 and the gypsum strips are bonded and fixed to the bent inner walls of the gypsum board 11;

[0060] Step S3: Install the hanger rod 2 at a predetermined position on the top (roof or floor) of the building structure through expansion bolts, and fix the main keel 3 to the hanger rod 2 in a predetermined direction;

[0061] Step S4: Connect the ceiling modules 1 after the final setting of the gypsum sticky mass or 3M glue to the buckles 31 at the corresponding positions on the main keels 3 at the corresponding positions one by one according to a predetermined rule, that is, the installation of the ceiling modules 1 is completed by connecting the covering keels 12 on the ceiling modules 1 to the buckles 31 at the corresponding positions one by one;

[0062] Step S5: Repeat step S4 to install several ceiling modules 1 one by one to form a modular ceiling system of a predetermined shape.

[0063] The contents described above may be implemented individually or in combination in various ways, and these variations are all within the protection scope of the present invention.

[0064] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the statement "comprise a ..." do not exclude the presence of other identical elements in the process, method, article or device comprising the elements.

[0065] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them. Although the present invention has been described in detail with reference to the above embodiments, a person skilled in the art should understand that the technical solutions described in the above embodiments can still be modified, or some of the technical features can be replaced by equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A modular ceiling system, characterized in that: The modular ceiling system comprises a plurality of ceiling modules (1), a suspension rod (2) fixed to the top of a building, and a main keel (3) fixedly connected to the bottom end of the suspension rod (2), wherein the ceiling modules (1) are connected to the main keel (3), and adjacent ceiling modules (1) are not connected to each other, and adjacent ceiling modules (1) can be arranged in contact with each other or arranged at intervals; The ceiling module (1) comprises a gypsum board (11) with a decorative layer and at least two facing keels (12) arranged parallel to each other on a non-decorative surface of the gypsum board (11), wherein the facing keels (12) are clamped with the main keels (3); The four edges of the gypsum board (11) are bent toward the non-decorative surface of the gypsum board (11) at a preset height, and the adjacent ends of the four edges of the gypsum board (11) are fixedly connected by an adhesive, the preset height is equal to the thickness of the covering keel (12), and the bent edges of the gypsum board (11) can cover the covering keel (12) arranged on the non-decorative surface; The gypsum board (11) is provided with V-shaped back grooves at the bending positions of the four sides thereof, and the angles of the V-shaped back grooves are acute angles, right angles or obtuse angles; The suspended ceiling module (1) further comprises an adhesive layer (13), wherein the adhesive layer (13) is located between the gypsum board (11) and the covering keel (12); The ceiling module (1) further comprises a reinforcement layer (14) and a plurality of reinforcement members (15); the reinforcement layer (14) is located between the gypsum board (11) and the covering keel (12); the reinforcement layer (14) and the gypsum board (11) are fixedly connected via an adhesive layer (13); and the reinforcement layer (14) and the covering keel (12) are fixedly connected via the reinforcement members (15); The covering keel (12) is a card-type keel; The modular ceiling system further comprises a plurality of clips (4) arranged at intervals on the main keel (3), and the covering keel (12) is connected to the clips (4); The construction method of the modular ceiling system comprises the following steps: The four sides of the gypsum board (11) are bent to a preset height toward the opposite side of the decorative surface of the gypsum board (11), and the adjacent ends of the four sides of the gypsum board (11) are fixedly connected by an adhesive; At least two mutually parallel covering keels (12) are fixed on the opposite sides of the decorative surface of the gypsum board (11); Installing the suspension rod (2) at a predetermined position on the top of the building, and fixedly connecting the main keel (3) to the suspension rod (2) in a predetermined direction; The covering keel (12) on the gypsum board (11) is connected to a preset position of the corresponding main keel (3).

2. The modular ceiling system according to claim 1, characterized in that: The depth of the V-shaped back groove is less than the thickness of the gypsum board (11).

3. The modular ceiling system according to claim 1, characterized in that: The reinforcement layer (14) comprises gypsum board strips and / or gypsum plasterboard.

4. The modular ceiling system according to claim 1, characterized in that: The step of bending the four edges of the gypsum board (11) to a preset height towards the opposite sides of the decorative surface of the gypsum board (11) comprises: A V-shaped back groove is provided on the surface opposite to the decorative surface of the gypsum board (11) at a preset distance from the edge, and the excess material at the corner formed by the intersection of adjacent V-shaped back grooves is removed, and then the edge of the gypsum board (11) is bent along the V-shaped back groove toward the non-decorative surface of the gypsum board (11).

Images