Ceiling system

Abstract

There is provided a ceiling system comprising: at least one elongate carrier configured to be suspended from an overhead structure, the elongate carrier having an upper side and a lower side; a ceiling element coupled to the elongate carrier; wherein the lower side of the elongate carrier has a coupling recess at which the ceiling element is coupled to the elongate carrier; the coupling recess has first and second projections, formed respectively on a first side of the coupling recess and a second side of the coupling recess, which is on an opposite side of the coupling recess from the first side; the ceiling element has first and second apertures formed on opposite sides of the ceiling element and configured such that, when the ceiling element is inserted in the coupling recess of the elongate carrier, the first aperture of the ceiling element can receive the first projection of the coupling recess and the second aperture of the ceiling element can receive the second projection of the coupling recess; and the first projection in the coupling recess is closer to the lower side of the elongate carrier than the second projection.

Description

[0001] CEILING SYSTEM

[0002] The following disclosure relates to a ceiling system, in particular a suspended ceiling system.

[0003] A variety of ceiling systems are known, in which ceiling elements are supported by carriers. It is desirable for such systems to be designed with consideration for the ease of installation while ensuring that the ceiling elements are securely coupled to the carriers once installed in order to minimise the risk of a ceiling element falling from a ceiling system, which may risk injury to people in the space below and / or damage.

[0004] It may be desirable to provide a ceiling system with improved ease of installation of ceiling elements to carriers that maintains reliability of installation.

[0005] According to the invention, there is provided a ceiling system as defined in the appended claims.

[0006] Embodiments will be more clearly understood from the following description, given by way of example only, with reference to the accompanying drawings in which:

[0007] Figure 1 illustrates a ceiling system;

[0008] Figure 2 illustrates a coupling of a ceiling element to a carrier in a ceiling system according to Figure 1;

[0009] Figures 3 to 5 illustrate the steps required to couple and uncouple a ceiling element to and from a carrier;

[0010] Figure 6 illustrates any alternative configuration of a coupling recess; and

[0011] Figure 7 illustrates a ceiling element supported by first and second elongate carriers, shown in cross-section.

[0012] Figure 1 depicts an example of a ceiling system 10 according to the present disclosure. In the arrangement depicted in Figure 10, a plurality of ceiling elements 11 are coupled to an elongate carrier 12. It should be appreciated that any number of ceiling elements 11 may be coupled to an elongate carrier 12. Each ceiling element 11 may be coupled to one or more elongate carriers 12 in order to support the weight of the ceiling element 11. For example, the ceiling element 11 may extend between, and be coupled to, at least first and second elongate carriers 12.

[0013] In an arrangement as depicted in Figure 1, the one or more elongate carriers 12, may in turn be connected to and supported by one or more suspension hangers 13 that are connected to an overhead structure. Each elongate carrier 12 may be supported by at least two suspension hangers 13 for stability. Alternative arrangements for mounting the elongate carriers 12, such as directly connecting the elongate carriers 12 to an overhead structure, may also be used.

[0014] Figure 1 depicts the ceiling elements 11 in cross-section, for the convenience of explaining the configuration of the coupling of the ceiling element 11 to the elongate carrier 12. It should be appreciated, however, that the ceiling element 11 may extend into the plane of the Figure. For example, the ceiling element 11 may be elongate in a direction perpendicular to the plane of Figure 1. For clarity, in the present disclosure, this direction may be referred to as the length of the ceiling element 11. The height of a ceiling element 11 may refer to its size in a vertical direction when installed. However, it should be appreciated that the use of these terms does not imply any relative size of the ceiling element in these directions. Accordingly, for example, the ceiling element 11 may be larger in its length direction than its height. Equally, the ceiling element 11 may be smaller in its length direction than its height.

[0015] Figure 2 depicts in more detail an example of an arrangement for coupling a ceiling element 11 to an elongate carrier 12 according to the present disclosure. As shown, the elongate carrier 12 has an upper side 15 and a lower side 16. In the lower side 16 of the elongate carrier 12 one or more coupling recesses 20 are provided, into which the ceiling element 11 may be at least partially inserted in order to couple the ceiling element 11 to the elongate carrier 12. The coupling recess 20 has a first side 25 and a second side 26 provided on opposite sides of the coupling recess 20. The first and second side 25, 26 of the coupling recess 20 may be on opposite sides of the coupling recess 20 in a direction that is parallel to the length of the elongate carrier 12. The first side 25 of the coupling recess 20 includes a first projection 21. The second side 26 of the coupling recess 20 includes a second projection 22.

[0016] Correspondingly, the ceiling element 11 has a first side 37, configured to engage with the first side 25 of the coupling recess 20. The ceiling element 11 has a second side 38, on the opposite side of the ceiling element 11 from the first side 37, that is configured to engage with the second side 26 of the coupling recess 20. The ceiling element 11 additionally includes a first aperture 31 provided on the first side 37 of the ceiling element 11 and a second aperture 32 provided on the second side 38 of the ceiling element 11.

[0017] The ceiling element 11 and the coupling recess 20 within the elongate carrier 12 are configured such that, when the ceiling element 11 is inserted in the coupling recess 20, the first aperture 31 of the ceiling element 11 can receive the first projection 21 of the coupling recess 20 and the second aperture 32 of the ceiling element 11 can receive the second projection 22 of the coupling recess 20.

[0018] When the ceiling element 11 is inserted into and coupled to the coupling recess 20 of the elongate carrier 12, one part 35 of the ceiling element 11 is received within the coupling recess 20 of the elongate carrier 12 and another part 36 extends away from the lower side 16 of the elongate carrier 12. The ceiling element 11 may also extend away from the coupling recess 20 parallel to its length direction on one or both sides of the elongate carrier 12.

[0019] As shown in Figure 2, the ceiling element 11 and the coupling recess 20 of the elongate carrier 12 are configured such that the first aperture 31 and the first projection 21 are arranged closer to the lower side 16 of the elongate carrier 12 than the second aperture 32 of the ceiling element 11 and the second projection 22 of the coupling recess 20. In such an arrangement, the weight of the ceiling element 11, acting downwards in the arrangement depicted in Figure 2 acts about the engagement of the first projection 21 within the first aperture 31 to generate a moment, in a clockwise direction in the arrangement depicted in Figure 2. This moment is resisted by the second projection 22 of the coupling recess 20 engaging with the second aperture 32 of the ceiling element 11, forcing engagement of the second projection 22 into the second aperture 32. In such an arrangement, therefore, the weight of the ceiling element forces the first and second projections 21, 22 into the first and second apertures 31, 32 respectively. This provides a secure mechanism to couple the ceiling element 11 to the elongate carrier 12 without requiring separate fixings or tools.

[0020] Such a coupling arrangement is both secure and simple to install. This may be beneficial because it may be necessary to couple a ceiling element 11 to an elongate carrier 12 while working at height. Additionally, as is explained below, although the ceiling element 11 is held securely when it is coupled to an elongate carrier 12 by such an arrangement, it can also readily be uncoupled from the elongate carrier 12. This may be beneficial for maintenance of the ceiling system 10 and / or to facilitate provision of access to the space above the ceiling system 10.

[0021] Figures 3, 4 and 5 depict the process of uncoupling a ceiling element 11 from an elongate carrier 12 and, in reverse, the process of coupling a ceiling element 11 to an elongate carrier 12. In particular, Figure 3 depicts a ceiling element 11 coupled to an elongate carrier 12. As explained above, in this position, the first projection 21 of the coupling recess 20 of the elongate carrier 12 is inserted into the first aperture 31 of the ceiling element 11 and the second projection 22 of the coupling recess 20 is inserted into the second aperture 32 of the ceiling element 11, securely coupling the ceiling element 11 to the elongate carrier 12.

[0022] As shown in the arrangement depicted in Figures 3, 4 and 5, the coupling recess 20 further comprises an indentation 28 in the first side 25 of the coupling recess 20. The indentation 28 is provided above the first projection 21 of the coupling recess. This enables the ceiling element 11 to rotate about an axis parallel to its length, namely a direction perpendicular to the plane of the image shown in Figure 3, 4 and 5, while the first projection 21 remains engaged with the first aperture 31.

[0023] In such an arrangement, the engagement of the first projection of the coupling recess 20 with the first aperture 31 of the ceiling element 11 may act as a fulcrum. The indentation 28 in the coupling recess 20 may be configured such that, the ceiling element 11 rotate in a direction that results in the second projection 22 of the coupling recess 20 being disengaged from the second aperture 32 of the ceiling element 11, namely in the anticlockwise direction in the arrangement depicted in Figures 3, 4 and 5. During such rotation, the section of the ceiling element 11 that is above the first aperture 31 of the ceiling element 11 can be accommodated within the space provided by the indentation 28 of the coupling recess 20. Figure 4 depicts the ceiling element 11 and the elongate carrier 12 after completion of such a rotation, at which point the ceiling element 11 is partially uncoupled from the coupling recess of the elongate carrier 12.

[0024] Figure 5 depicts the ceiling element 11 and elongate carrier 12 after the next step in the uncoupling process. In particular, the coupling recess 20 is configured such that, after rotating the ceiling element 11 about the engagement of the first projection 21 of the coupling recess 20 and the first aperture 31 of the ceiling element 11, the ceiling element 11 can be translated relative to the coupling recess 20, for example horizontally. This movement enables the first project 21 of the coupling recess 20 to be removed from the first aperture 31 of the ceiling element 11. As shown in Figure 5, in this position, neither of the projections 21, 22 are engaged with their respective apertures 31, 32. The ceiling element 11 may therefore be removed from the coupling recess by translating it at an oblique angle to the elongate carrier 12, decoupling the ceiling element 11 from the elongate carrier 12.

[0025] Although the above describes the process of uncoupling a ceiling element 11 from an elongate carrier 12 as a first step of rotating the ceiling element 11 relative to the elongate carrier 12, a second step of translating the ceiling element 11 horizontally relative to elongate carrier 12 and a third step of translating the ceiling element 11 at an oblique angle relative to the elongate carrier, in practice a user may combine two or more of these steps into one motion rather than performing them as distinct steps. Alternatively or additionally, it may be possible to disengage the first and second projections 21, 22 from their respective apertures 31, 32 simultaneously simply by rotating the ceiling element 11 relative to the elongate carrier 12.

[0026] The shapes of the first and second projections 21, 22 and / or the corresponding apertures 31, 32 may be selected to control the required movement in order to uncouple the ceiling element 11 from the elongate carrier 12. It will be appreciated that a balance may be sought between making it sufficiently easy for the ceiling element 11 to be uncoupled from the elongate carrier 12, for example to facilitate maintenance, while ensuring that it is sufficiently securely coupled to the elongate carrier 12 to ensure that accidental release of a ceiling element 11 from the ceiling system 10 is minimised.

[0027] In the arrangement depicted in Figures 2 to 5, the first and second projections 21, 25 have a simple triangular shape. This may be easy to manufacture compared to other shapes of projections and / or may be more robust. Figure 6 depicts an alternative arrangement of a coupling recess 40 from that depicted in Figures 2 to 5. As shown, in the arrangement depicted in Figure 6, the first and second projections 41, 42 of the coupling recess 40 have a small flange or ledge that extends from the respective side 43, 44 of the coupling recess 40 towards the other side of the coupling recess 43, 44. This may provide a more secure coupling between the ceiling element 11 and the elongate carrier 12. Other shapes of projections may be used.

[0028] It will be appreciated that in order to couple a ceiling element 11 to an elongate carrier, the above-described decoupling process may be reversed. In particular, a ceiling element 11 may initially be inserted into a coupling recess 20 of the elongate carrier at an oblique angle to the position shown in Figure 5. The ceiling element 11 may then be translated relative to the coupling recess 20 in order to engage the first project 21 of the coupling recess 20 with the first recess 31 of the ceiling element 11, as shown in Figure 4. Finally, the ceiling element 11 may be rotated about the engagement between the first projection 21 of the coupling recess 20 with the first aperture 31 of the ceiling element 11 until the second projection 22 of the coupling recess 20 engages with the second aperture 32 of the ceiling element 11.

[0029] In an arrangement in which the elongate carrier has plural coupling recesses 20, the separation between adjacent coupling recesses 20 may be configured such that, when a ceiling element 11 is rotated to the partially uncoupled position, namely the position depicted in Figure 4, the ceiling element 11 does not come into contact with a ceiling element coupled to an adjacent coupling recess.

[0030] It will be appreciated that the size of separation required between adjacent coupling recesses 20 may be determined by the height of the ceiling elements 11 to be used in the ceiling system. Alternatively, the height of ceiling elements 11 that may be used in a ceiling system may be determined based on the separation of the coupling recesses in an elongate carrier 12 to be used in the ceiling system 10. In either case, ensuring adequate separation is provided between ceiling elements 11 when at least one is rotated to the partially uncoupled position may facilitate coupling and decoupling ceiling elements from an elongate carrier 12 in any desired order.

[0031] In some arrangements, the spacing between coupling recesses 20 may be sufficiently large to retain space for an operator’s fingers between adjacent ceiling elements 11 while one ceiling element 11 is rotated to the partially uncoupled position. It should also be appreciated that in a ceiling system 10, as an alternative to an arrangement with evenly spaced coupling recesses 20 and / or matching ceiling elements 11, elongate carriers 12 may have varying separations between adjacent coupling recesses 20 and / or ceiling elements 11 may be used that have varying heights from each other.

[0032] One or both of the first and second apertures 31, 32 of the ceiling element 11 may be a blind aperture, namely not extend all the way through the ceiling element 11 between the first and second sides 37, 38 of the ceiling element 11. Alternatively, at least one of the first and second apertures 31, 32 may be a through-hole. In an arrangement, one or both of the first and second apertures 31, 32 of the ceiling element 11 may be provided in the form of a groove that extends the length of the ceiling element 11. Such an arrangement may facilitate the manufacture of the ceiling element 11, for example, in comparison with an alternative arrangement in which plural apertures are provided on each of the two sides 37, 38 of the ceiling element 11 in order to couple the ceiling element 11 to respective coupling recesses 20 of two or more elongate carriers 12.

[0033] In an arrangement, a ceiling system 10 may have first and second elongate carriers 12, each having respective coupling recesses 20, and a ceiling element 11 that extends at least between the first and second elongate carriers 12 and is coupled to the respective coupling recesses 20 of the first and second elongate carriers 12. In such an arrangement, one or both of the first and second apertures 31, 32 of the ceiling element may be sufficiently elongate that the aperture 31, 32 can receive the corresponding projection 21, 22 of both of the coupling recesses 20 of the first and second elongate carriers 12.

[0034] It will be appreciated that an arrangement having long elongate apertures 31, 32, including an arrangement in which the aperture 31, 32 is a groove extending along the length of the ceiling element 11, may facilitate the coupling of a ceiling element 11 to an elongate carrier 12 because the projection 21, 22 may engage with a corresponding aperture 31, 32 regardless of deviations of the position of the ceiling element 11 relative to the elongate carrier 12 in a direction along the length of the ceiling element 11.

[0035] As explained above, when a ceiling element 11 is coupled to a coupling recess 20 of an elongate carrier 12 according to the present disclosure, the weight of the ceiling element 11 drives the first and second projections 21, 22 of the coupling recess 20 into the first and second apertures 31, 32 of the ceiling element 11 in order to provide the secure coupling.

[0036] In an arrangement, the weight of the ceiling element may be supplemented by the provision of a biasing member that is configured to exert a force between the elongate carrier 12 and the ceiling element 11 in the same direction as the weight of the ceiling element 11. For example, the biasing member may be mounted to either one of the elongate carrier 12 and the ceiling element 11 and be configured to engage with the other of the elongate carrier 12 and the ceiling element 11 as the ceiling element 11 is inserted into the coupling recess 20. Such a biasing member may be configured such that on insertion of the ceiling element 11 into the coupling recess 20 of the elongate carrier 12, the biasing member is elastically deformed generating a force to revert the biasing member to its undeformed shape.

[0037] In an arrangement, the ceiling element 11 may be formed from a solid elongate beam of material. For example, the ceiling element 11 may be formed from wood. It will be appreciated that other materials may be used and / or that hollow or partially hollow beams may be used. A solid beam may be convenient for its ease of manufacture and because it may provide a ceiling element 11 with sufficient weight in order to ensure that the first and second projections 21, 22 of the coupling recess 20 engage securely with the first and second apertures 31, 32 of the ceiling element.

[0038] The elongate carrier 12 may be provided in any convenient form in order to provide a sufficiently strong ceiling system 10. Similarly, it may be formed from any conventional choice of material for forming a ceiling system 10. In an arrangement, the elongate carrier 12 may be formed from a U-shaped cross-section metal beam, for example formed from steel or aluminium. Figure 7 depicts in cross-section such an arrangement, in which first and second elongate carriers 12 support a ceiling element 11. As shown, the elongate carriers 12 include an elongate base 51 and first and second elongate walls 52 extending away from the base 51. In such an arrangement, the coupling recess 20 may be formed as first and second cut-away sections in the first and second elongate sidewalls 52, respectively. The first and second cut-away sections may be aligned such that a ceiling element 11 can be inserted into both cut-away sections.

[0039] In an arrangement, each of the first and second cut-away sections in the first and second elongate sidewalls 52 of an elongate carrier 12 may have a respective first projection on the first side of the coupling recess 20 and a respective second projection provided on the second side of the coupling recess. Accordingly, the coupling recess may have a pair of first projects provided on the first side of the coupling recess and a pair of second projections formed on the second side of the coupling recess. Both of the first projections may engage with one first aperture 31, or a respective first aperture 31, formed on the first side 37 of the ceiling element 11 and both of the second projections may engage with one second aperture 32, or a respective second aperture 32, formed on the second side 38 of the ceiling element 11. Such an arrangement may provide a stable coupling of the ceiling element 11 to the elongate carrier 12.

[0040] It should be appreciated, however, that variations of the arrangement described above using a U-shaped cross-section elongate carrier are possible. For example, one or both of the first and second cut-away sections may not include one of the projections. For example, one of the first and second cut-away sections in the first and second elongate sidewalls may not include either of the first and second projections. In an alternative arrangement, one of the first and second cut-away sections in the first and second elongate sidewalls may have one of the first and second projections 21, 22 and the other of the first and second cut-away sections may have the other of the first and second projections 21, 22.

[0041] The elongate carrier 12 may also be implemented in other forms. For example it may be provided as a solid beam, or a flat strip of material oriented such that its planar surface extends vertically, with a cut-out section in its lower surface to provide a coupling recess 20.

[0042] These and other features and advantages of the present disclosure will be readily apparent from the detailed description, the scope of the invention being set out in the appended claims.

[0043] The present disclosure is set forth in various levels of detail in this application and no limitation as to the scope of the claimed subject matter is intended by either the inclusion or non-inclusion of elements, components, or the like in the summary. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood that the claimed subject matter is not necessarily limited to the particular embodiments or arrangements illustrated herein. The accompanying drawings are provided for purposes of illustration only, and the dimensions, positions, order, and relative sizes reflected in the drawings attached hereto may vary. The detailed description will be better understood in conjunction with the accompanying drawings, with reference made in detail to embodiments of the present subject matter, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the present subject matter, not limitation of the present subject matter. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the present subject matter. Thus, it is intended that the present subject matter covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0044] In the foregoing description, it will be appreciated that the phrases “at least one”, “one or more”, and “and / or”, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. All directional references (e.g., proximal, distal, upper, lower, upward, downward, left, right, lateral, longitudinal, front, back, top, bottom, above, below, vertical, horizontal, radial, axial, clockwise, counter clockwise, and / or the like) are only used for identification purposes to aid the reader’s understanding of the present disclosure, and / or serve to distinguish regions of the associated elements from one another, and do not limit the associated element, particularly as to the position, orientation, or use of this disclosure.

Claims

CLAIMS1. A ceiling system comprising: at least one elongate carrier configured to be suspended from an overhead structure, the elongate carrier having an upper side and a lower side; a ceiling element coupled to the elongate carrier; wherein the lower side of the elongate carrier has a coupling recess at which the ceiling element is coupled to the elongate carrier; the coupling recess has first and second projections, formed respectively on a first side of the coupling recess and a second side of the coupling recess, which is on an opposite side of the coupling recess from the first side; the ceiling element has first and second apertures formed on opposite sides of the ceiling element and configured such that, when the ceiling element is inserted in the coupling recess of the elongate carrier, the first aperture of the ceiling element can receive the first projection of the coupling recess and the second aperture of the ceiling element can receive the second projection of the coupling recess; and the first projection in the coupling recess is closer to the lower side of the elongate carrier than the second projection.

2. The ceiling system of claim 1, wherein the coupling recess comprises an indentation in the first side of the recess, above the first projection, that is configured such that the ceiling element, with the first projection received in the first aperture of the ceiling element, can rotate about an axis parallel to its length between a coupled position in which the second projection is received in the second aperture of the ceiling element, and a partially uncoupled position in which the second projection is removed from the second aperture.

3. The ceiling system of claim 2, wherein the coupling recess is configured such that, when the ceiling element is rotated to the partially uncoupled position within the coupling recess, the ceiling element can be translated relative to the coupling recess in order to remove the first projection of the coupling recess from the first aperture of the ceiling element in order to decouple the ceiling element from the coupling recess.

4. The ceiling system of claim 2 or 3, wherein the elongate carrier has plural coupling recesses and a separation between adjacent coupling recesses is configured such that, when the ceiling element is rotated to the partially uncoupled position, it is not in contact with a ceiling element coupled to an adjacent coupling recess that is in the coupled position.

5. The ceiling system of any one of the preceding claims, wherein at least one of the first and second apertures of the ceiling element is a blind aperture.

6. The ceiling system of claim 5, wherein at least one of the first and second apertures of the ceiling element is a groove extending the length of the ceiling element.

7. The ceiling system of any one of the preceding claims, comprising first and second elongate carriers, each having respective coupling recesses, wherein the ceiling element extends at least between the first and second elongate carriers and is coupled to the respective coupling recesses of the first and second elongate carriers.

8. The ceiling system of claim 7, wherein at least one of the first and second apertures of the ceiling element is elongate such that the aperture can receive the corresponding projection of a coupling recess of the first elongate carrier and the corresponding projection of a coupling recess of the second elongate carrier.

9. The ceiling system of any one of the preceding claims, wherein, when the ceiling element is coupled to the elongate carrier, part of the ceiling element is received in the coupling recess of the elongate carrier and part of the ceiling element extends away from the lower side of the elongate carrier.

10. The ceiling system of any one of the preceding claims, wherein the ceiling element and the coupling recess are configured such that the weight of the ceiling element encourages the first and second projections into the first and second apertures, respectively.

11. The ceiling system of claim 10, wherein the coupling recess of the elongate carrier further comprises a biasing member, configured to exert a force between the elongate carrier and the ceiling element in the same direction as the weight of the ceiling element.

12. The ceiling system of any one of the preceding claims wherein the ceiling element is formed from a solid elongate beam of material.

13. The ceiling system of claim 12, wherein the ceiling element is formed from wood.

14. The ceiling system of any one of the preceding claims, wherein the elongate carrier comprises an elongate base and first and second elongate side walls extending away from the base; and the coupling recess is formed as first and second cut-away sections in the first and second elongate side walls that are aligned with each other.

15. The ceiling system of claim 14, wherein the coupling recess comprises a pair of first projections formed in the first and second cut-away sections of the first and second elongate side walls on the first side of the coupling recess and a pair of second projections formed in the first and second cut-away section of the first and second elongate side walls on the second side of the coupling recess.

16. The ceiling system of any one of the preceding claims, wherein the ceiling system comprises a plurality of ceiling elements.

17. The ceiling system of any one of the preceding claims, wherein the elongate carrier includes at least two suspension points, separated from one another in the elongate direction of the elongate carrier, at which the elongate carrier is suspended from the overhead structure.

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