Ceiling systems and beams

Abstract

A ceiling system includes a plurality of beams arranged in an intersecting manner to form a lattice, the plurality of beams intersecting one another at beam intersection nodes, each of the plurality of beams extending along a longitudinal beam axis from a first end to a second end and having a bottom, a top, a first side surface extending upward from the bottom to the top, a second side surface opposite the first side surface and extending upward from the bottom to the top, and a transverse width measured from the first side surface to the second side surface. The transverse width of at least one of the plurality of beams varies along the longitudinal beam axis for at least a section of the at least one of the plurality of beams.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 67 / 778,723, filed Mar. 27, 2025, the entirety of which is incorporated herein by reference.BACKGROUND

[0002] Building structures, such as acoustics structures, baffles, and beams for ceiling and wall systems, are designed to balance interests with respect to aesthetics, material cost, structural integrity, acoustics, and environmental impact.

[0003] Accordingly, those skilled in the art continue research and development in the field of acoustic building structures.SUMMARY

[0004] This summary is intended merely to introduce a simplified summary of some aspects of one or more implementations of the present disclosure. Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description below.

[0005] Disclosed is a ceiling system.

[0006] In one example, the ceiling system includes a plurality of beams arranged in an intersecting manner to form a lattice, the plurality of beams intersecting one another at beam intersection nodes, each of the plurality of beams extending along a longitudinal beam axis from a first end to a second end and having a bottom, a top, a first side surface extending upward from the bottom to the top, a second side surface opposite the first side surface and extending upward from the bottom to the top, and a transverse width measured from the first side surface to the second side surface. The transverse width of at least one of the plurality of beams varies along the longitudinal beam axis for at least a section of the at least one of the plurality of beams.

[0007] In one example, the plurality of beams include a first beam and a second beam, the first beam intersecting the second beam at a first beam intersection node, the first beam includes first and second sections located on opposite sides of the first beam intersection node; the transverse width of the first section of the first beam decreasing with axial distance from the first beam intersection node; and the transverse width of the second section of the first beam decreasing with axial distance from the first beam intersection node.

[0008] In one example, the second beam includes first and second sections located on opposites sides of the first beam intersection node; the transverse width of the first section of the second beam decreasing with axial distance from the first beam intersection node; and the transverse width of the second section of the second beam decreasing with axial distance from the first beam intersection node. In one example, the second beam extends orthogonal to the first beam.

[0009] In one example, the first section of the first beam having a distal end and the second section of the first beam having a proximal end; the first section of the second beam having a distal end and the second section of the second beam having a proximal end; and each of the distal end of the first section of the first beam, the proximal end of the second section of the first beam, the distal end of the first section of the second beam, and the proximal end of the second section of the second beam include engagement features that interlock with one another.

[0010] In one example, the plurality of beams includes a third beam, the first beam intersecting the third beam at a second beam intersection node that is spaced from the first beam intersection node along the first beam, the second section of the first beam extending between the first beam intersection node and the second beam intersection node, the first beam further includes a third section, the second and third sections of the first beam located on opposite sides of the second beam intersection node; the transverse width of the second section of the first beam increasing with axial distance from the second beam intersection node; and the transverse width of the third section of the first beam increasing with axial distance from the second beam intersection node.

[0011] In one example, the third beam includes first and second sections located on opposites sides of the second beam intersection node; the transverse width of the first section of the third beam increasing with axial distance from the second beam intersection node; and the transverse width of the second section of the second beam increasing with axial distance from the first beam intersection node. In one example, the third beam extends parallel to the second beam.

[0012] In one example, the plurality of beams includes a fourth beam includes a first section, a second section, and a third section; the fourth beam intersecting the second beam at a third intersection node that is spaced from the first intersection node along the second beam; the fourth beam intersecting the third beam at a fourth beam intersection node that is spaced from the third beam intersection node along the fourth beam, the fourth beam intersection node spaced from the second beam intersection node along the third beam; the first and second sections of the fourth beam located on opposite sides of the third beam intersection node, the second section of the fourth beam extending between the third beam intersection node and the fourth beam intersection node, the second and third sections of the fourth beam located on opposite sides of the fourth beam intersection node; the second section of the second beam extending between the first intersection node and the third intersection node, the second beam further includes a third section, the second and third sections of the second beam located on opposite sides of the second intersection node; the transverse width of the second section of the second beam increasing with axial distance from the third intersection node; the transverse width of the third section of the second beam increasing with axial distance from the third intersection node; the transverse width of the first section of the fourth beam increasing with axial distance from the third intersection node; the transverse width of the second section of the fourth beam increasing with axial distance from the third intersection node; the transverse width of the second section of the second beam decreasing with axial distance from the fourth intersection node; the transverse width of the third section of the second beam decreasing with axial distance from the fourth intersection node; the transverse width of the second section of the fourth beam decreasing with axial distance from the fourth intersection node; and the transverse width of the third section of the fourth beam decreasing with axial distance from the fourth intersection node.

[0013] In one example, each of the beam intersection nodes extends along a node axis that is orthogonal to the beam axes; the first beam intersection node having a first transverse cross-sectional area; and the second beam intersection node having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0014] In one example, the first transverse cross-sectional area is defined by a first reference quadrilateral having corner points defined by intersection points of the side surfaces of the first and second beams and wherein the second transverse cross-sectional area is defined by a second reference quadrilateral having corner points defined by intersection points of the side surfaces of the first and third beams.

[0015] In one example, the first beam intersection node includes a first type of hanger assembly; and the second beam intersection node includes a second type of hanger assembly that is different than the first type of hanger assembly.

[0016] In one example, the first type of hanger assembly includes a plug assembly includes a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly includes a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.

[0017] In one example, each beam of the plurality of beams is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0018] In one example, each beam of the plurality of beams includes a transverse height measured from the bottom to the top; and wherein the transverse height of the at least one of the plurality of beams varies along the longitudinal beam axis for at least the section of the at least one of the plurality of beams.

[0019] In one example, a ceiling system includes a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end and includes a plurality of sections, each of the plurality of sections having a transverse width that varies with distance from the first end and a transverse height that varies with distance from the first end; and the beams arranged in an intersecting manner to form a lattice includes a plurality of beam intersection nodes.

[0020] In one example, for each of the plurality of sections of each of the plurality of beams, as the transverse width increases, the transverse height decreases. In one example, for each of the plurality of beams, the plurality of sections includes tapering sections and widening sections arranged in an alternating manner along the beam axis, the transverse width of each of the tapering sections decreasing with axial distance from the first end, and the transverse width of each of the widening sections increasing with axial distance from the first end.

[0021] In one example, for each of the plurality of beams, the transverse height each of the tapering sections increases with axial distance from the first end, and the transverse height of each of the widening sections decreases with axial distance from the first end.

[0022] In one example, for each of the plurality of beams, the transverse height each of the tapering sections decreases with axial distance from the first end, and the transverse height of each of the widening sections increases with axial distance from the first end.

[0023] In one example, each of the plurality of beams is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0024] In one example, the plurality of beam intersection nodes includes a plurality of first beam intersection nodes having a first transverse cross-sectional area and a plurality of second beam intersection nodes having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0025] In one example, each of the first and second transverse cross-sectional areas is defined by a reference quadrilateral having corner points defined by intersection points of side surfaces of the plurality of beams.

[0026] In one example, each of the first beam intersection nodes includes a first type of hanger assembly; and each of the second beam intersection nodes includes a second type of hanger assembly that is different than the first type of hanger assembly.

[0027] In one example, each of the first type of hanger assemblies includes a plug assembly includes a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein each of the second type of hanger assemblies includes a second mounting plate coupled to tops of the beam and configured to be coupled to a second hanger to hang the lattice from the support structure.

[0028] A ceiling system includes: a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end; and the beams arranged in an intersecting manner to form a lattice includes at least two different types of beam intersection nodes.

[0029] In one example, the at least two different types of beam intersection nodes includes at least one first beam intersection node and at least one second beam intersection node; and wherein the at least one first beam intersection node includes a first transverse cross-sectional area and the at least one second beam intersection node includes a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0030] In one example, the at least two different types of beam intersection nodes includes at least one first beam intersection node and at least one second beam intersection node; and the at least one first beam intersection node includes a first type of hanger assembly and the at least second beam intersection node includes a second type of hanger assembly that is different than the first type of hanger assembly.

[0031] In one example, the first type of hanger assembly includes a plug assembly includes a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly includes a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.

[0032] In one example, each beam of the plurality of beams is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0033] In one example, an acoustic ceiling beam includes a first end; a second end; a beam axis extending from the first end to the second end; a plurality of tapering sections, each of the tapering sections having a transverse width that decreases with axial distance from the first end; a plurality of widening section, each of the widening sections having a transverse width that increases with axial distance from the first end; the tapering sections and the widening sections arranged in an alternating manner along the beam axis; and wherein the acoustic ceiling beam is formed of an acoustic material.

[0034] In one example, the transverse height each of the tapering sections increases with axial distance from the first end, and the transverse height of each of the widening sections decreases with axial distance from the first end.

[0035] In one example, each of the tapering sections decreases with axial distance from the first end, and the transverse height of each of the widening sections increases with axial distance from the first end. In one example, the acoustic material is felt. In one example, the acoustical ceiling beam is a hollow beam structure formed by one or more folded sheets of material.DESCRIPTION OF THE DRAWINGS

[0036] The detailed description of the disclosure will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities of the examples shown in the drawings.

[0037] FIG. 1 is a bottom, front, right perspective view of a ceiling system;

[0038] FIG. 2 is a top, front, right perspective view of the ceiling system of FIG. 1;

[0039] FIG. 3 is a top view of the ceiling system of FIG. 1;

[0040] FIG. 4 is an exploded view of a portion of the ceiling system of FIG. 1;

[0041] FIG. 5A is a portion of the ceiling system of FIG. 1;

[0042] FIG. 5B is an exploded view of FIG. 5A;

[0043] FIG. 5C is a top view of a portion of the ceiling system of FIG. 1;

[0044] FIG. 6 is an exploded view of a portion of the ceiling system of FIG. 1;

[0045] FIG. 7A is a top view of a portion of the ceiling system of FIG. 1;

[0046] FIG. 7B is a top view of a portion of the ceiling system of FIG. 1;

[0047] FIG. 8A is a side view of a portion of the ceiling system of FIG. 1;

[0048] FIG. 8B is a side view of a portion of the ceiling system of FIG. 1;

[0049] FIG. 9 is a bottom, front, right perspective view of a ceiling system;

[0050] FIG. 10 is a top, front, right perspective view of the ceiling system of FIG. 9;

[0051] FIG. 11 is a bottom, front, right perspective view of a ceiling system; and

[0052] FIG. 12 is a top, front, right perspective view of the ceiling system of FIG. 11.DETAILED DESCRIPTION

[0053] For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the art will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0054] As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical species. The terms “a” (or “an”), “one or more” and “at least one” may be used interchangeably herein. The terms “comprising”, “including”, “containing”, and “having” may be used interchangeably. The term “include” should be interpreted as “include, but are not limited to”. The term “including” should be interpreted as “including, but are not limited to”.

[0055] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range.

[0056] According to the present application, use of the term “about” in conjunction with a numeral value refers to a value that may be + / −5% of that numeral. As used herein, the term “substantially free” is intended to mean an amount less than about 5.0 wt. %, less than 3.0 wt. %, less than 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition.

[0057] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, patent applications, publications, and other references cited or referred to herein are incorporated by reference in their entireties for all purposes. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

[0058] In the description of examples disclosed herein, 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 disclosure. Relative terms such as “lower,”“upper,”“horizontal,”“vertical,”, “above,”“below,”“up,”“down,”“top” and “bottom” as well as derivatives thereof (e.g., “horizontally,”“downwardly,”“upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing (if applicable) under discussion. These relative terms are for convenience of description only and, unless specified otherwise, do not require that the apparatus be constructed or operated in a particular orientation.

[0059] As used herein, terms such as “attached,”“affixed,”“connected,”“coupled,”“interconnected,” and the like refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Accordingly, the disclosure is not limited to such examples illustrating certain combinations of features that may exist alone or in combination with other features.

[0060] The present disclosure relates to ceiling systems, and more particularly to ceiling systems having tapered beams. The ceiling systems may include architectural fixtures, specifically acoustical tapered beams, having desired acoustic material properties. Examples include structures having 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 plenum above the ceiling. In one or more examples, the disclosure has an NRC rating ranging from about 0.55 to about 0.95.

[0061] Referring to FIGS. 1 to 12, disclosed is a ceiling system 10. The ceiling system 10 is configured to be suspended from an overhead support structure 12, such as a ceiling. The ceiling system 10 may be coupled to or suspended from an overhead support structure 12 via one or more suspension structures as described herein.

[0062] The ceiling system 10 comprises a plurality of beams 102 arranged in an intersecting manner to form a lattice 100. The plurality of beams 102 intersect one another at beam intersection nodes 120. Each of the plurality of beams 102 extends along a longitudinal beam axis AL from a first end 102a to a second end 102b. Each of the plurality of beams 102 has a bottom 101, a top 103, a first side surface 105 extending upward from the bottom 101 to the top 103, and a second side surface 107 opposite the first side surface 105 and extending upward from the bottom 101 to the top 10. In one example, each of the plurality of beams 102 has a transverse width W measured from the first side surface 105 to the second side surface 107.

[0063] In one or more examples, each of the plurality of beams 102 has an end cap 109 defining at least one of the first end 102a and the second end 102b. The end cap 109 may be a single, monolithic piece. In another example, the end cap 109 may be defined by a single, monolithic piece defining the bottom 101, top 103, first side surface 105, and second side surface 107. In a further example, the end cap 109 includes three pieces 109a, 109b, and 109c that collectively define the end cap 109 when coupled together. The end cap 109 may be comprised of a felt material.

[0064] In one or more examples, the transverse width W of at least one of the plurality of beams 102 varies along the longitudinal beam axis AL for at least a section of the at least one of the plurality of beams 102 such that it is tapered.

[0065] In one or more examples, the plurality of beams 102 includes a first beam 150 and a second beam 160. The first beam 150 intersects the second beam 160 at a first beam intersection node 120a. The first beam 150 includes at least a first section 150a and second section 150b located on opposite sides of the first beam intersection node 120a.

[0066] In one or more examples, the transverse width W is different in the first section 150a and second section 150b of the first beam 150. In one example, the transverse width W150a of the first section 150a of the first beam 150 decreases with axial distance from the first beam intersection node 120a and the transverse width W150b of the second section 150b of the first beam 150 decreases with axial distance from the first beam intersection node 120a.

[0067] The second beam 160 includes a first section 160a and second section 160b located on opposites sides of the first beam intersection node 120a. In one or more examples, the transverse width W160a of the first section 160a of the second beam 160 is different than the transverse width W160b of the second section 160b of the second beam 160. In one example, the transverse width W160a of the first section 160a of the second beam 160 decreases with axial distance from the first beam intersection node 120a and the transverse width W160b of the second section 160b of the second beam 160 decreases with axial distance from the first beam intersection node 120a. In one example, the second beam 160 extends orthogonal to the first beam 150.

[0068] The first beam 150 has a transverse height H measured from the bottom 151 to the top 153. The first section 150a of the first beam has a transverse height H150a, the first section 150b has a transverse height H150b, and the first section 150c has a transverse height H150c. The transverse height H150a, the transverse height H150b, and the transverse height H150c may vary within each respective section.

[0069] The second beam 160 has a transverse height H measured from the bottom 161 to the top 163. The first section 160a of the second beam has a transverse height H160a, the second section 160b has a transverse height H160b, and the second section 160c has a transverse height H160c. The transverse height H160a, the transverse height H160b, and the transverse height H160c may vary within each respective section.

[0070] In one or more examples, the first section 150a of the first beam 150 has a distal end and the second section 150b of the first beam 150 has a proximal end. The first section 160b of the second beam 160 having a distal end and the second section 160b of the second beam 160 has a proximal end. In one example, each of the distal end of the first section 150a of the first beam 150, the proximal end of the second section 150b of the first beam 150, the distal end of the first section 160a of the second beam 160, and the proximal end of the second section 160b of the second beam 160 comprise engagement features 110 that interlock with one another, see FIG. 4 and FIGS. 5a-5c.

[0071] As shown in FIGS. 5a-5c, the plurality of beams 102 intersect at intersection nodes 120. The intersection nodes 120 may include engagement portions 113 integrally formed into the plurality of beams 102 for coupling the plurality of beams 102 in the lattice 100 formation. The plurality of beams 102 may be further coupled together with an engagement bracket 112, an engagement plate 114, and intersection fasteners 116. The plurality of beams 102 may further define an intersection base 115 within the intersection nodes 120.

[0072] In one or more examples, the plurality of beams 102 include a third beam 170. The first beam 150 intersects the third beam 170 at a second beam intersection node 120b that is spaced from the first beam intersection node 120a along the first beam 150. The second section 150b of the first beam 150 extends between the first beam intersection node 120a and the second beam intersection node 120b. The first beam 150 further may include a third section 150c. In one example, the second section 150b and third section 150c of the first beam 150 are located on opposite sides of the second beam intersection node 120b.

[0073] In one or more examples, the transverse width W150b of the second section 150b of the first beam 150 increases with axial distance from the second beam intersection node 120b and the transverse width W150c of the third section 150c of the first beam 150 increasing with axial distance from the second beam intersection node 120b.

[0074] The third beam 170 has a transverse height H measured from the bottom 171 to the top 173. The first section 170a of the third beam has a transverse height H170a, the second section 170b has a transverse height H170b, and the third section 170c has a transverse height H170c. The transverse height H170a, the transverse height H170b, and the transverse height H170c may vary within each respective section.

[0075] The third beam 170 includes a first section 170a and second section 170b located on opposites sides of the second beam intersection node 120b. In one example, the transverse width W170a of the first section 170a of the third beam 170 increases with axial distance from the second beam intersection node 120b and the transverse width W160b of the second section 160b of the second beam 160 increases with axial distance from the first beam intersection node 120a. In one example, the third beam 170 extends parallel to the second beam 160.

[0076] In one or more examples, the plurality of beams 102 includes a fourth beam 180 comprising a first section 180a, a second section 180b, and a third section 180c. The fourth beam 180 intersects the second beam 160 at a third intersection node 120c that is spaced from the first intersection node 120a along the second beam 160.

[0077] The fourth beam 180 has a transverse height H measured from the bottom 181 to the top 183. The first section 180a of the fourth beam has a transverse height H180a, the second section 180b has a transverse height H180b, and the third section 180c has a transverse height H180c. The transverse height H180a, the transverse height H180b, and the transverse height H180c may vary within each respective section.

[0078] The fourth beam 180 intersects the third beam 170 at a fourth beam intersection node 120 that is spaced from the third beam 170 intersection node 120 along the fourth beam 180, the fourth beam intersection node 120 spaced from the second beam intersection node 120b along the third beam 170.

[0079] The first section 180a and second section 180b of the fourth beam 180 are located on opposite sides of the third beam intersection node 120c. In one example, the second section 180b of the fourth beam 180 extending between the third beam intersection node 120c and the fourth beam intersection node 120d, the second section 180b and third section 180c of the fourth beam 180 located on opposite sides of the fourth beam intersection node 120d.

[0080] The second section 160b of the second beam 160 extends between the first intersection node 120a and the third intersection node 120c. In one example, the second beam 160 further includes a third section 160c. The second section 160b and third section 160c of the second beam 160 are located on opposite sides of the second intersection node 120b. In one example, the transverse width W160b of the second section 160b of the second beam 160 increases with axial distance from the third intersection node 120c and the transverse width W160c of the third section 160c of the second beam 160 increases with axial distance from the third intersection node 120c. Further, the transverse width W180a of the first section 180a of the fourth beam 180 increases with axial distance from the third intersection node 120c and the transverse width W180b of the second section 180b of the fourth beam 180 increases with axial distance from the third intersection node 120c. In one example, the transverse width W160b of the second section 160b of the second beam 160 decreases with axial distance from the fourth intersection node 120d, the transverse width W160c of the third section 160c of the second beam 160 decreases with axial distance from the fourth intersection node 120d, the transverse width W180b of the second section 180b of the fourth beam 180 decreases with axial distance from the fourth intersection node 120d, and the transverse width W180c of the third section 180c of the fourth beam 180 decreases with axial distance from the fourth intersection node 120d.

[0081] In one or more examples, each of the beam intersection nodes 120a, 120b, 120c, and 120d extends along a node axis AN that is orthogonal to the longitudinal beam axis AL. The first beam intersection node 120a has a first transverse cross-sectional area and the second beam intersection node 120b has a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0082] In one or more examples, the first transverse cross-sectional area is defined by a first reference quadrilateral 190 having corner points 190a, 190b, 190c, 190d defined by intersection points of the side surfaces of the first beam 150 and second beam 160 and wherein the second transverse cross-sectional area is defined by a second reference quadrilateral 192 having corner points 192a, 192b, 192c, 192d defined by intersection points of the side surfaces of the first beam 150 and third beam 170.

[0083] In one or more examples, the first beam intersection node 120a comprises a first type of hanger assembly 130. In one example, the first type of hanger assembly 130 comprises a plug assembly 132 comprising a first mounting plate 134 embedded in the plug 132 and configured to be coupled to a first hanger 136 to hang the lattice 100 from an overhead support structure 12.

[0084] In one or more examples, the second beam intersection node 120b comprises a second type of hanger assembly 140 that is different than the first type of hanger assembly 130. In one example, the second type of hanger assembly 140 comprises a second mounting plate 142 coupled to the tops 103 of the third beam 170 and configured to be coupled to a second hanger 144 to hang the lattice 100 from the overhead support structure 12.

[0085] In one or more examples, each of the plurality of beams 102 of the ceiling system 10 is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams 102 is a hollow beam structure formed by one or more folded sheets of material.

[0086] In one or more examples, each of the plurality of beams 102 comprises a transverse height H measured from the bottom 101 to the top 103. In one example, the transverse height H of the at least one of the plurality of beams 102 varies along the longitudinal beam axis AL for at least the section of the at least one of the plurality of beams 102.

[0087] The ceiling system 10 may be defined by a plurality of beams 102, each of the beams 102 extending along a longitudinal beam axis AL L from a first end 102a to a second end 102b and comprising a plurality of sections. In one example, each of the plurality of sections has a transverse width W that varies with distance from the first end 102a and a transverse height H that varies with distance from the first end 102a. In another example, the beams 102 are arranged in an intersecting manner to form a lattice 100 comprising a plurality of beam intersection nodes 120.

[0088] In one example, for each of the plurality of sections of each of the plurality of beams 102, as the transverse width W increases, the transverse height H decreases. In another example, for each of the plurality of sections of each of the plurality of beams 102, as the transverse width W increases, the transverse height H increases.

[0089] In one example, for each of the plurality of beams 102, the plurality of sections comprises tapering sections and widening sections arranged in an alternating manner along the longitudinal beam axis AL. The transverse width W of each of the tapering sections may decrease with axial distance from the first end 102a, and the transverse width W of each of the widening sections may increase with axial distance from the first end 102a.

[0090] In one example, for each of the plurality of beams 102, the transverse height H each of the tapering sections increases with axial distance from the first end 102a, and the transverse height H of each of the widening sections decreases with axial distance from the first end 102a.

[0091] In one example, for each of the plurality of beams 102, the transverse height H each of the tapering sections decreases with axial distance from the first end 102a, and the transverse height H of each of the widening sections increases with axial distance from the first end 102a.

[0092] In one example, each of the plurality of beams 102 is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams 102 is a hollow beam structure formed by one or more folded sheets of material.

[0093] In one example, the plurality of beam intersection nodes 120 comprises a plurality of first beam intersection nodes 120a having a first transverse cross-sectional area and a plurality of second beam intersection nodes 120b having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0094] In one example, each of the first and second transverse cross-sectional areas is defined by a reference quadrilateral 190 having corner points defined by intersection points of side surfaces of the plurality of beams 102.

[0095] In one example, each of the first beam intersection nodes 120a comprises a first type of hanger assembly 130. In one example, each of the first type of hanger assemblies 130 comprises a plug assembly 132 comprising a first mounting plate 134 embedded in the plug and configured to be coupled to a first hanger 136 to hang the lattice 100 from an overhead support structure 12.

[0096] In one example, each of the second beam 160 intersection nodes 120 comprises a second type of hanger assembly 140 that is different than the first type of hanger assembly 130. In one example, each of the second type of hanger assemblies 140 comprises a second mounting plate 142 coupled to tops of the beam and configured to be coupled to a second hanger 144 to hang the lattice 100 from the support structure 12.

[0097] In one or more examples, the ceiling system 10 includes a plurality of beams 102, each of the beams 102 extending along a longitudinal beam axis AL from a first end 102a to a second end 102b. The plurality of beams 102 may be arranged in an intersecting manner to form a lattice 100 comprising at least two different types of beam intersection nodes 120a, 120b.

[0098] In one or more examples, the at least two different types of beam intersection nodes 120a, 120b comprises at least one first beam intersection node 120a and at least one second beam intersection node 120b. In one example, the at least one first beam intersection node 120a comprises a first transverse cross-sectional area and the at least one second beam intersection node 120b comprises a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0099] In another example, the at least two different types of beam intersection nodes 120 comprise at least one first beam intersection node 120a and at least one second beam intersection node 120b. The at least one first beam intersection node 120a comprises a first type of hanger assembly 130 and the at least second beam intersection node 120b comprises a second type of hanger assembly 140 that is different than the first type of hanger assembly 130.In one example, the first type of hanger assembly 130 comprises a plug assembly 132 comprising a first mounting plate 134 embedded in the plug and configured to be coupled to a first hanger 136 to hang the lattice 100 from an overhead support structure 12, and the second type of hanger 140 comprises a second mounting plate 142 coupled to the tops of the third beam 170 and configured to be coupled to a second hanger 144 to hang the lattice 100 from the overhead support structure 12.

[0100] In one or more examples, each of the plurality of beams 102 is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams 102 is a hollow beam structure formed by one or more folded sheets of material.

[0101] Also disclosed is an acoustic ceiling beam 102. In one example, the acoustic ceiling beam 102 includes a first end 102a, a second end 102b, a longitudinal beam axis AL extending from the first end 102a to the second end 102b, and a plurality of tapering sections. Each of the tapering sections has a transverse width W that decreases with axial distance from the first end 102a, a plurality of widening sections, and each of the widening sections having a transverse width W that increases with axial distance from the first end 102a. In one example, the tapering sections and the widening sections are arranged in an alternating manner along the longitudinal beam axis AL. In another example, the acoustic ceiling beam is formed of an acoustic material.

[0102] In one example, transverse height H each of the tapering sections increases with axial distance from the first end 102a, and the transverse height H of each of the widening sections decreases with axial distance from the first end 102a.

[0103] In one or more examples, each of the tapering sections decreases with axial distance from the first end 102a, and the transverse height H of each of the widening sections increases with axial distance and the first end 102a.

[0104] In one example, the acoustic material is felt. In another example, the acoustical ceiling beam 102 is a hollow beam structure formed by one or more folded sheets of material.

[0105] Referring to FIG. 9 and FIG. 10, in one or more examples, each of the plurality of beams 102 may abut a frame 111. The frame 111 may cover every end 102a and 102b of each of the plurality of beams 102 forming the lattice 100. In one example, the frame 111 is comprised of a single, monolithic structure. In another example, the frame 111 is comprised of two or more structures coupled together. The frame 111 may be comprised of the same material, such as a felt material, as each of the plurality of beams 102.

[0106] Referring to FIGS. 11 and 12, the lattice 100 may include a plurality of beams 102 having more than four beams. The lattice 100 may have any number of a plurality of beams 102, including 6, 7, 8, 9, 10, or more beams.

[0107] The disclosed may be characterized by the following Exemplary Claims.

[0108] Exemplary Claim 1. A ceiling system comprising: a plurality of beams arranged in an intersecting manner to form a lattice, the plurality of beams intersecting one another at beam intersection nodes, each of the plurality of beams extending along a longitudinal beam axis from a first end to a second end and comprising: a bottom; a top; a first side surface extending upward from the bottom to the top; a second side surface opposite the first side surface and extending upward from the bottom to the top; and a transverse width measured from the first side surface to the second side surface; and wherein the transverse width of at least one of the plurality of beams varies along the longitudinal beam axis for at least a section of the at least one of the plurality of beams.

[0109] Exemplary Claim 2. The ceiling system according to Exemplary Claim 1 further comprising: the plurality of beams comprising a first beam and a second beam, the first beam intersecting the second beam at a first beam intersection node, the first beam comprising first and second sections located on opposite sides of the first beam intersection node; the transverse width of the first section of the first beam decreasing with axial distance from the first beam intersection node; and the transverse width of the second section of the first beam decreasing with axial distance from the first beam intersection node.

[0110] Exemplary Claim 3. The ceiling system according to Exemplary Claim 2 further comprising: the second beam comprising first and second sections located on opposites sides of the first beam intersection node; the transverse width of the first section of the second beam decreasing with axial distance from the first beam intersection node; and the transverse width of the second section of the second beam decreasing with axial distance from the first beam intersection node.

[0111] Exemplary Claim 4. The ceiling system according to any one of exemplary claims 2 to 3 wherein the second beam extends orthogonal to the first beam.

[0112] Exemplary Claim 5. The ceiling system according to any one of exemplary claims 2 to 4 further comprising: the first section of the first beam having a distal end and the second section of the first beam having a proximal end; the first section of the second beam having a distal end and the second section of the second beam having a proximal end; and each of the distal end of the first section of the first beam, the proximal end of the second section of the first beam, the distal end of the first section of the second beam, and the proximal end of the second section of the second beam comprise engagement features that interlock with one another.

[0113] Exemplary Claim 6. The ceiling system according to any one of exemplary claims 2 to 5 further comprising: the plurality of beams comprising a third beam, the first beam intersecting the third beam at a second beam intersection node that is spaced from the first beam intersection node along the first beam, the second section of the first beam extending between the first beam intersection node and the second beam intersection node, the first beam further comprising a third section, the second and third sections of the first beam located on opposite sides of the second beam intersection node; the transverse width of the second section of the first beam increasing with axial distance from the second beam intersection node; and the transverse width of the third section of the first beam increasing with axial distance from the second beam intersection node.

[0114] Exemplary Claim 7. The ceiling system according to Exemplary Claim 6 further comprising: the third beam comprising first and second sections located on opposites sides of the second beam intersection node; the transverse width of the first section of the third beam increasing with axial distance from the second beam intersection node; and the transverse width of the second section of the second beam increasing with axial distance from the first beam intersection node.

[0115] Exemplary Claim 8. The ceiling system according to any one of exemplary claims 6 to 7 wherein the third beam extends parallel to the second beam.

[0116] Exemplary Claim 9. The ceiling system according to any one of exemplary claims 6 to 8 further comprising: the plurality of beams comprising a fourth beam comprising a first section, a second section, and a third section; the fourth beam intersecting the second beam at a third intersection node that is spaced from the first intersection node along the second beam; the fourth beam intersecting the third beam at a fourth beam intersection node that is spaced from the third beam intersection node along the fourth beam, the fourth beam intersection node spaced from the second beam intersection node along the third beam; the first and second sections of the fourth beam located on opposite sides of the third beam intersection node, the second section of the fourth beam extending between the third beam intersection node and the fourth beam intersection node, the second and third sections of the fourth beam located on opposite sides of the fourth beam intersection node; the second section of the second beam extending between the first intersection node and the third intersection node, the second beam further comprising a third section, the second and third sections of the second beam located on opposite sides of the second intersection node; the transverse width of the second section of the second beam increasing with axial distance from the third intersection node; the transverse width of the third section of the second beam increasing with axial distance from the third intersection node; the transverse width of the first section of the fourth beam increasing with axial distance from the third intersection node; the transverse width of the second section of the fourth beam increasing with axial distance from the third intersection node; the transverse width of the second section of the second beam decreasing with axial distance from the fourth intersection node; the transverse width of the third section of the second beam decreasing with axial distance from the fourth intersection node; the transverse width of the second section of the fourth beam decreasing with axial distance from the fourth intersection node; and the transverse width of the third section of the fourth beam decreasing with axial distance from the fourth intersection node.

[0117] Exemplary Claim 10. The ceiling system according to any one of exemplary claims 6 to 9 further comprising: each of the beam intersection nodes extending along a node axis that is orthogonal to the beam axes; the first beam intersection node having a first transverse cross-sectional area; and the second beam intersection node having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0118] Exemplary Claim 11. The ceiling system according to Exemplary Claim 10 wherein the first transverse cross-sectional area is defined by a first reference quadrilateral having corner points defined by intersection points of the side surfaces of the first and second beams and wherein the second transverse cross-sectional area is defined by a second reference quadrilateral having corner points defined by intersection points of the side surfaces of the first and third beams.

[0119] Exemplary Claim 12. The ceiling system according to any one of exemplary claims 6 to 11 further comprising: the first beam intersection node comprising a first type of hanger assembly; and the second beam intersection node comprising a second type of hanger assembly that is different than the first type of hanger assembly.

[0120] Exemplary Claim 13. The ceiling system according to Exemplary Claim 12 wherein the first type of hanger assembly comprises a plug assembly comprising a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly comprises a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.

[0121] Exemplary Claim 14. The ceiling system according to any one of exemplary claims 1 to 13 wherein each of the plurality of beams is formed of an acoustic material.

[0122] Exemplary Claim 15. The ceiling system according to Exemplary Claim 14 wherein the acoustic material is felt.

[0123] Exemplary Claim 16. The ceiling system according to any one of exemplary claims 1 to 15 wherein each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0124] Exemplary Claim 17. The ceiling system according to any one of exemplary claims 1 to 16 wherein each of the plurality of beams comprises a transverse height measured from the bottom to the top; and wherein the transverse height of the at least one of the plurality of beams varies along the longitudinal beam axis for at least the section of the at least one of the plurality of beams.

[0125] Exemplary Claim 18. A ceiling system comprising: a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end and comprising a plurality of sections, each of the plurality of sections having a transverse width that varies with distance from the first end and a transverse height that varies with distance from the first end; and the beams arranged in an intersecting manner to form a lattice comprising a plurality of beam intersection nodes.

[0126] Exemplary Claim 19. The ceiling system according to Exemplary Claim 18 wherein for each of the plurality of sections of each of the plurality of beams, as the transverse width increases, the transverse height decreases.

[0127] Exemplary Claim 20. The ceiling system according to any one of exemplary claims 18 to 19 wherein, for each of the plurality of beams, the plurality of sections comprise tapering sections and widening sections arranged in an alternating manner along the beam axis, the transverse width of each of the tapering sections decreasing with axial distance from the first end, and the transverse width of each of the widening sections increasing with axial distance from the first end.

[0128] Exemplary Claim 21. The ceiling system according to Exemplary Claim 20 wherein, for each of the plurality of beams, the transverse height each of the tapering sections increases with axial distance from the first end, and the transverse height of each of the widening sections decreases with axial distance from the first end.

[0129] Exemplary Claim 22. The ceiling system according to Exemplary Claim 20 wherein, for each of the plurality of beams, the transverse height each of the tapering sections decreases with axial distance from the first end, and the transverse height of each of the widening sections increases with axial distance from the first end.

[0130] Exemplary Claim 23. The ceiling system according to any one of exemplary claims 18 to 22 wherein each of the plurality of beams is formed of an acoustic material.

[0131] Exemplary Claim 24. The ceiling system according to Exemplary Claim 23 wherein the acoustic material is felt.

[0132] Exemplary Claim 25. The ceiling system according to any one of exemplary claims 18 to 24 wherein each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0133] Exemplary Claim 26. The ceiling system according to any one of exemplary claims 18 to 25 wherein the plurality of beam intersection nodes comprises a plurality of first beam intersection nodes having a first transverse cross-sectional area and a plurality of second beam intersection nodes having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0134] Exemplary Claim 27. The ceiling system according to Exemplary Claim 26 wherein each of the first and second transverse cross-sectional areas is defined by a reference quadrilateral having corner points defined by intersection points of side surfaces of the plurality of beams.

[0135] Exemplary Claim 28. The ceiling system according to any one of exemplary claims 26 to 27 further comprising: each of the first beam intersection nodes comprising a first type of hanger assembly; and each of the second beam intersection nodes comprising a second type of hanger assembly that is different than the first type of hanger assembly.

[0136] Exemplary Claim 29. The ceiling system according to Exemplary Claim 28 wherein each of the first type of hanger assemblies comprises a plug assembly comprising a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein each of the second type of hanger assemblies comprises a second mounting plate coupled to tops of the beam and configured to be coupled to a second hanger to hang the lattice from the support structure.

[0137] Exemplary Claim 30. A ceiling system comprising: a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end; and the beams arranged in an intersecting manner to form a lattice comprising at least two different types of beam intersection nodes.

[0138] Exemplary Claim 31. The ceiling system according to Exemplary Claim 30 wherein the at least two different types of beam intersection nodes comprises at least one first beam intersection node and at least one second beam intersection node; and wherein the at least one first beam intersection node comprises a first transverse cross-sectional area and the at least one second beam intersection node comprises a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0139] Exemplary Claim 31. The ceiling system according to any one of exemplary claims 30 wherein the at least two different types of beam intersection nodes comprises at least one first beam intersection node and at least one second beam intersection node; and the at least one first beam intersection node comprises a first type of hanger assembly and the at least second beam intersection node comprises a second type of hanger assembly that is different than the first type of hanger assembly.

[0140] Exemplary Claim 32. The ceiling system according to Exemplary Claim 31 wherein the first type of hanger assembly comprises a plug assembly comprising a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly comprises a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.

[0141] Exemplary Claim 33. The ceiling system according to any one of exemplary claims 30 to 32 wherein each of the plurality of beams is formed of an acoustic material.

[0142] Exemplary Claim 34. The ceiling system according to Exemplary Claim 14 wherein the acoustic material is felt.

[0143] Exemplary Claim 35. The ceiling system according to any one of exemplary claims 30 to 34 wherein each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0144] Exemplary Claim 37. An acoustic ceiling beam comprising: a first end; a second end; a beam axis extending from the first end to the second end; a plurality of tapering sections, each of the tapering sections having a transverse width that decreases with axial distance from the first end; a plurality of widening section, each of the widening sections having a transverse width that increases with axial distance from the first end; the tapering sections and the widening sections arranged in an alternating manner along the beam axis; and wherein the acoustic ceiling beam is formed of an acoustic material.

[0145] Exemplary Claim 38. The acoustic ceiling beam according to Exemplary Claim 37 wherein the transverse height each of the tapering sections increases with axial distance from the first end, and the transverse height of each of the widening sections decreases with axial distance from the first end.

[0146] Exemplary Claim 38. The acoustic ceiling beam according to Exemplary Claim 37 wherein each of the tapering sections decreases with axial distance from the first end, and the transverse height of each of the widening sections increases with axial distance from the first end.

[0147] Exemplary Claim 39. The acoustic ceiling beam according to Exemplary Claim 37 wherein the acoustic material is felt.

[0148] Exemplary Claim 40. The acoustic ceiling beam according to any one of exemplary claims 37 to 39 wherein the acoustical ceiling beams is a hollow beam structure formed by one or more folded sheets of material.

[0149] While the present disclosure has been described with reference to several examples, which examples have been set forth in considerable detail for the purposes of making a complete disclosure of the disclosure, such examples are merely representative and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the disclosure. The scope of the disclosure is to be determined from the claims appended hereto. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the disclosure.

Examples

Embodiment Construction

[0053]For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the art will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0054]As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical species. The terms “a” (or “an”), “one or more” and “at least one” may be used...

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 67 / 778,723, filed Mar. 27, 2025, the entirety of which is incorporated herein by reference.BACKGROUND

[0002] Building structures, such as acoustics structures, baffles, and beams for ceiling and wall systems, are designed to balance interests with respect to aesthetics, material cost, structural integrity, acoustics, and environmental impact.

[0003] Accordingly, those skilled in the art continue research and development in the field of acoustic building structures.SUMMARY

[0004] This summary is intended merely to introduce a simplified summary of some aspects of one or more implementations of the present disclosure. Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description below.

[0005] Disclosed is a ceiling system.

[0006] In one example, the ceiling system includes a plurality of beams arranged in an intersecting manner to form a lattice, the plurality of beams intersecting one another at beam intersection nodes, each of the plurality of beams extending along a longitudinal beam axis from a first end to a second end and having a bottom, a top, a first side surface extending upward from the bottom to the top, a second side surface opposite the first side surface and extending upward from the bottom to the top, and a transverse width measured from the first side surface to the second side surface. The transverse width of at least one of the plurality of beams varies along the longitudinal beam axis for at least a section of the at least one of the plurality of beams.

[0007] In one example, the plurality of beams include a first beam and a second beam, the first beam intersecting the second beam at a first beam intersection node, the first beam includes first and second sections located on opposite sides of the first beam intersection node; the transverse width of the first section of the first beam decreasing with axial distance from the first beam intersection node; and the transverse width of the second section of the first beam decreasing with axial distance from the first beam intersection node.

[0008] In one example, the second beam includes first and second sections located on opposites sides of the first beam intersection node; the transverse width of the first section of the second beam decreasing with axial distance from the first beam intersection node; and the transverse width of the second section of the second beam decreasing with axial distance from the first beam intersection node. In one example, the second beam extends orthogonal to the first beam.

[0009] In one example, the first section of the first beam having a distal end and the second section of the first beam having a proximal end; the first section of the second beam having a distal end and the second section of the second beam having a proximal end; and each of the distal end of the first section of the first beam, the proximal end of the second section of the first beam, the distal end of the first section of the second beam, and the proximal end of the second section of the second beam include engagement features that interlock with one another.

[0010] In one example, the plurality of beams includes a third beam, the first beam intersecting the third beam at a second beam intersection node that is spaced from the first beam intersection node along the first beam, the second section of the first beam extending between the first beam intersection node and the second beam intersection node, the first beam further includes a third section, the second and third sections of the first beam located on opposite sides of the second beam intersection node; the transverse width of the second section of the first beam increasing with axial distance from the second beam intersection node; and the transverse width of the third section of the first beam increasing with axial distance from the second beam intersection node.

[0011] In one example, the third beam includes first and second sections located on opposites sides of the second beam intersection node; the transverse width of the first section of the third beam increasing with axial distance from the second beam intersection node; and the transverse width of the second section of the second beam increasing with axial distance from the first beam intersection node. In one example, the third beam extends parallel to the second beam.

[0012] In one example, the plurality of beams includes a fourth beam includes a first section, a second section, and a third section; the fourth beam intersecting the second beam at a third intersection node that is spaced from the first intersection node along the second beam; the fourth beam intersecting the third beam at a fourth beam intersection node that is spaced from the third beam intersection node along the fourth beam, the fourth beam intersection node spaced from the second beam intersection node along the third beam; the first and second sections of the fourth beam located on opposite sides of the third beam intersection node, the second section of the fourth beam extending between the third beam intersection node and the fourth beam intersection node, the second and third sections of the fourth beam located on opposite sides of the fourth beam intersection node; the second section of the second beam extending between the first intersection node and the third intersection node, the second beam further includes a third section, the second and third sections of the second beam located on opposite sides of the second intersection node; the transverse width of the second section of the second beam increasing with axial distance from the third intersection node; the transverse width of the third section of the second beam increasing with axial distance from the third intersection node; the transverse width of the first section of the fourth beam increasing with axial distance from the third intersection node; the transverse width of the second section of the fourth beam increasing with axial distance from the third intersection node; the transverse width of the second section of the second beam decreasing with axial distance from the fourth intersection node; the transverse width of the third section of the second beam decreasing with axial distance from the fourth intersection node; the transverse width of the second section of the fourth beam decreasing with axial distance from the fourth intersection node; and the transverse width of the third section of the fourth beam decreasing with axial distance from the fourth intersection node.

[0013] In one example, each of the beam intersection nodes extends along a node axis that is orthogonal to the beam axes; the first beam intersection node having a first transverse cross-sectional area; and the second beam intersection node having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0014] In one example, the first transverse cross-sectional area is defined by a first reference quadrilateral having corner points defined by intersection points of the side surfaces of the first and second beams and wherein the second transverse cross-sectional area is defined by a second reference quadrilateral having corner points defined by intersection points of the side surfaces of the first and third beams.

[0015] In one example, the first beam intersection node includes a first type of hanger assembly; and the second beam intersection node includes a second type of hanger assembly that is different than the first type of hanger assembly.

[0016] In one example, the first type of hanger assembly includes a plug assembly includes a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly includes a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.

[0017] In one example, each beam of the plurality of beams is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0018] In one example, each beam of the plurality of beams includes a transverse height measured from the bottom to the top; and wherein the transverse height of the at least one of the plurality of beams varies along the longitudinal beam axis for at least the section of the at least one of the plurality of beams.

[0019] In one example, a ceiling system includes a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end and includes a plurality of sections, each of the plurality of sections having a transverse width that varies with distance from the first end and a transverse height that varies with distance from the first end; and the beams arranged in an intersecting manner to form a lattice includes a plurality of beam intersection nodes.

[0020] In one example, for each of the plurality of sections of each of the plurality of beams, as the transverse width increases, the transverse height decreases. In one example, for each of the plurality of beams, the plurality of sections includes tapering sections and widening sections arranged in an alternating manner along the beam axis, the transverse width of each of the tapering sections decreasing with axial distance from the first end, and the transverse width of each of the widening sections increasing with axial distance from the first end.

[0021] In one example, for each of the plurality of beams, the transverse height each of the tapering sections increases with axial distance from the first end, and the transverse height of each of the widening sections decreases with axial distance from the first end.

[0022] In one example, for each of the plurality of beams, the transverse height each of the tapering sections decreases with axial distance from the first end, and the transverse height of each of the widening sections increases with axial distance from the first end.

[0023] In one example, each of the plurality of beams is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0024] In one example, the plurality of beam intersection nodes includes a plurality of first beam intersection nodes having a first transverse cross-sectional area and a plurality of second beam intersection nodes having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0025] In one example, each of the first and second transverse cross-sectional areas is defined by a reference quadrilateral having corner points defined by intersection points of side surfaces of the plurality of beams.

[0026] In one example, each of the first beam intersection nodes includes a first type of hanger assembly; and each of the second beam intersection nodes includes a second type of hanger assembly that is different than the first type of hanger assembly.

[0027] In one example, each of the first type of hanger assemblies includes a plug assembly includes a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein each of the second type of hanger assemblies includes a second mounting plate coupled to tops of the beam and configured to be coupled to a second hanger to hang the lattice from the support structure.

[0028] A ceiling system includes: a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end; and the beams arranged in an intersecting manner to form a lattice includes at least two different types of beam intersection nodes.

[0029] In one example, the at least two different types of beam intersection nodes includes at least one first beam intersection node and at least one second beam intersection node; and wherein the at least one first beam intersection node includes a first transverse cross-sectional area and the at least one second beam intersection node includes a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0030] In one example, the at least two different types of beam intersection nodes includes at least one first beam intersection node and at least one second beam intersection node; and the at least one first beam intersection node includes a first type of hanger assembly and the at least second beam intersection node includes a second type of hanger assembly that is different than the first type of hanger assembly.

[0031] In one example, the first type of hanger assembly includes a plug assembly includes a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly includes a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.

[0032] In one example, each beam of the plurality of beams is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0033] In one example, an acoustic ceiling beam includes a first end; a second end; a beam axis extending from the first end to the second end; a plurality of tapering sections, each of the tapering sections having a transverse width that decreases with axial distance from the first end; a plurality of widening section, each of the widening sections having a transverse width that increases with axial distance from the first end; the tapering sections and the widening sections arranged in an alternating manner along the beam axis; and wherein the acoustic ceiling beam is formed of an acoustic material.

[0034] In one example, the transverse height each of the tapering sections increases with axial distance from the first end, and the transverse height of each of the widening sections decreases with axial distance from the first end.

[0035] In one example, each of the tapering sections decreases with axial distance from the first end, and the transverse height of each of the widening sections increases with axial distance from the first end. In one example, the acoustic material is felt. In one example, the acoustical ceiling beam is a hollow beam structure formed by one or more folded sheets of material.DESCRIPTION OF THE DRAWINGS

[0036] The detailed description of the disclosure will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities of the examples shown in the drawings.

[0037] FIG. 1 is a bottom, front, right perspective view of a ceiling system;

[0038] FIG. 2 is a top, front, right perspective view of the ceiling system of FIG. 1;

[0039] FIG. 3 is a top view of the ceiling system of FIG. 1;

[0040] FIG. 4 is an exploded view of a portion of the ceiling system of FIG. 1;

[0041] FIG. 5A is a portion of the ceiling system of FIG. 1;

[0042] FIG. 5B is an exploded view of FIG. 5A;

[0043] FIG. 5C is a top view of a portion of the ceiling system of FIG. 1;

[0044] FIG. 6 is an exploded view of a portion of the ceiling system of FIG. 1;

[0045] FIG. 7A is a top view of a portion of the ceiling system of FIG. 1;

[0046] FIG. 7B is a top view of a portion of the ceiling system of FIG. 1;

[0047] FIG. 8A is a side view of a portion of the ceiling system of FIG. 1;

[0048] FIG. 8B is a side view of a portion of the ceiling system of FIG. 1;

[0049] FIG. 9 is a bottom, front, right perspective view of a ceiling system;

[0050] FIG. 10 is a top, front, right perspective view of the ceiling system of FIG. 9;

[0051] FIG. 11 is a bottom, front, right perspective view of a ceiling system; and

[0052] FIG. 12 is a top, front, right perspective view of the ceiling system of FIG. 11.DETAILED DESCRIPTION

[0053] For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the art will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0054] As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical species. The terms “a” (or “an”), “one or more” and “at least one” may be used interchangeably herein. The terms “comprising”, “including”, “containing”, and “having” may be used interchangeably. The term “include” should be interpreted as “include, but are not limited to”. The term “including” should be interpreted as “including, but are not limited to”.

[0055] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range.

[0056] According to the present application, use of the term “about” in conjunction with a numeral value refers to a value that may be + / −5% of that numeral. As used herein, the term “substantially free” is intended to mean an amount less than about 5.0 wt. %, less than 3.0 wt. %, less than 1.0 wt. %; preferably less than about 0.5 wt. %, and more preferably less than about 0.25 wt. % of the composition.

[0057] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, patent applications, publications, and other references cited or referred to herein are incorporated by reference in their entireties for all purposes. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

[0058] In the description of examples disclosed herein, 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 disclosure. Relative terms such as “lower,”“upper,”“horizontal,”“vertical,”, “above,”“below,”“up,”“down,”“top” and “bottom” as well as derivatives thereof (e.g., “horizontally,”“downwardly,”“upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing (if applicable) under discussion. These relative terms are for convenience of description only and, unless specified otherwise, do not require that the apparatus be constructed or operated in a particular orientation.

[0059] As used herein, terms such as “attached,”“affixed,”“connected,”“coupled,”“interconnected,” and the like refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Accordingly, the disclosure is not limited to such examples illustrating certain combinations of features that may exist alone or in combination with other features.

[0060] The present disclosure relates to ceiling systems, and more particularly to ceiling systems having tapered beams. The ceiling systems may include architectural fixtures, specifically acoustical tapered beams, having desired acoustic material properties. Examples include structures having 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 plenum above the ceiling. In one or more examples, the disclosure has an NRC rating ranging from about 0.55 to about 0.95.

[0061] Referring to FIGS. 1 to 12, disclosed is a ceiling system 10. The ceiling system 10 is configured to be suspended from an overhead support structure 12, such as a ceiling. The ceiling system 10 may be coupled to or suspended from an overhead support structure 12 via one or more suspension structures as described herein.

[0062] The ceiling system 10 comprises a plurality of beams 102 arranged in an intersecting manner to form a lattice 100. The plurality of beams 102 intersect one another at beam intersection nodes 120. Each of the plurality of beams 102 extends along a longitudinal beam axis AL from a first end 102a to a second end 102b. Each of the plurality of beams 102 has a bottom 101, a top 103, a first side surface 105 extending upward from the bottom 101 to the top 103, and a second side surface 107 opposite the first side surface 105 and extending upward from the bottom 101 to the top 10. In one example, each of the plurality of beams 102 has a transverse width W measured from the first side surface 105 to the second side surface 107.

[0063] In one or more examples, each of the plurality of beams 102 has an end cap 109 defining at least one of the first end 102a and the second end 102b. The end cap 109 may be a single, monolithic piece. In another example, the end cap 109 may be defined by a single, monolithic piece defining the bottom 101, top 103, first side surface 105, and second side surface 107. In a further example, the end cap 109 includes three pieces 109a, 109b, and 109c that collectively define the end cap 109 when coupled together. The end cap 109 may be comprised of a felt material.

[0064] In one or more examples, the transverse width W of at least one of the plurality of beams 102 varies along the longitudinal beam axis AL for at least a section of the at least one of the plurality of beams 102 such that it is tapered.

[0065] In one or more examples, the plurality of beams 102 includes a first beam 150 and a second beam 160. The first beam 150 intersects the second beam 160 at a first beam intersection node 120a. The first beam 150 includes at least a first section 150a and second section 150b located on opposite sides of the first beam intersection node 120a.

[0066] In one or more examples, the transverse width W is different in the first section 150a and second section 150b of the first beam 150. In one example, the transverse width W150a of the first section 150a of the first beam 150 decreases with axial distance from the first beam intersection node 120a and the transverse width W150b of the second section 150b of the first beam 150 decreases with axial distance from the first beam intersection node 120a.

[0067] The second beam 160 includes a first section 160a and second section 160b located on opposites sides of the first beam intersection node 120a. In one or more examples, the transverse width W160a of the first section 160a of the second beam 160 is different than the transverse width W160b of the second section 160b of the second beam 160. In one example, the transverse width W160a of the first section 160a of the second beam 160 decreases with axial distance from the first beam intersection node 120a and the transverse width W160b of the second section 160b of the second beam 160 decreases with axial distance from the first beam intersection node 120a. In one example, the second beam 160 extends orthogonal to the first beam 150.

[0068] The first beam 150 has a transverse height H measured from the bottom 151 to the top 153. The first section 150a of the first beam has a transverse height H150a, the first section 150b has a transverse height H150b, and the first section 150c has a transverse height H150c. The transverse height H150a, the transverse height H150b, and the transverse height H150c may vary within each respective section.

[0069] The second beam 160 has a transverse height H measured from the bottom 161 to the top 163. The first section 160a of the second beam has a transverse height H160a, the second section 160b has a transverse height H160b, and the second section 160c has a transverse height H160c. The transverse height H160a, the transverse height H160b, and the transverse height H160c may vary within each respective section.

[0070] In one or more examples, the first section 150a of the first beam 150 has a distal end and the second section 150b of the first beam 150 has a proximal end. The first section 160b of the second beam 160 having a distal end and the second section 160b of the second beam 160 has a proximal end. In one example, each of the distal end of the first section 150a of the first beam 150, the proximal end of the second section 150b of the first beam 150, the distal end of the first section 160a of the second beam 160, and the proximal end of the second section 160b of the second beam 160 comprise engagement features 110 that interlock with one another, see FIG. 4 and FIGS. 5a-5c.

[0071] As shown in FIGS. 5a-5c, the plurality of beams 102 intersect at intersection nodes 120. The intersection nodes 120 may include engagement portions 113 integrally formed into the plurality of beams 102 for coupling the plurality of beams 102 in the lattice 100 formation. The plurality of beams 102 may be further coupled together with an engagement bracket 112, an engagement plate 114, and intersection fasteners 116. The plurality of beams 102 may further define an intersection base 115 within the intersection nodes 120.

[0072] In one or more examples, the plurality of beams 102 include a third beam 170. The first beam 150 intersects the third beam 170 at a second beam intersection node 120b that is spaced from the first beam intersection node 120a along the first beam 150. The second section 150b of the first beam 150 extends between the first beam intersection node 120a and the second beam intersection node 120b. The first beam 150 further may include a third section 150c. In one example, the second section 150b and third section 150c of the first beam 150 are located on opposite sides of the second beam intersection node 120b.

[0073] In one or more examples, the transverse width W150b of the second section 150b of the first beam 150 increases with axial distance from the second beam intersection node 120b and the transverse width W150c of the third section 150c of the first beam 150 increasing with axial distance from the second beam intersection node 120b.

[0074] The third beam 170 has a transverse height H measured from the bottom 171 to the top 173. The first section 170a of the third beam has a transverse height H170a, the second section 170b has a transverse height H170b, and the third section 170c has a transverse height H170c. The transverse height H170a, the transverse height H170b, and the transverse height H170c may vary within each respective section.

[0075] The third beam 170 includes a first section 170a and second section 170b located on opposites sides of the second beam intersection node 120b. In one example, the transverse width W170a of the first section 170a of the third beam 170 increases with axial distance from the second beam intersection node 120b and the transverse width W160b of the second section 160b of the second beam 160 increases with axial distance from the first beam intersection node 120a. In one example, the third beam 170 extends parallel to the second beam 160.

[0076] In one or more examples, the plurality of beams 102 includes a fourth beam 180 comprising a first section 180a, a second section 180b, and a third section 180c. The fourth beam 180 intersects the second beam 160 at a third intersection node 120c that is spaced from the first intersection node 120a along the second beam 160.

[0077] The fourth beam 180 has a transverse height H measured from the bottom 181 to the top 183. The first section 180a of the fourth beam has a transverse height H180a, the second section 180b has a transverse height H180b, and the third section 180c has a transverse height H180c. The transverse height H180a, the transverse height H180b, and the transverse height H180c may vary within each respective section.

[0078] The fourth beam 180 intersects the third beam 170 at a fourth beam intersection node 120 that is spaced from the third beam 170 intersection node 120 along the fourth beam 180, the fourth beam intersection node 120 spaced from the second beam intersection node 120b along the third beam 170.

[0079] The first section 180a and second section 180b of the fourth beam 180 are located on opposite sides of the third beam intersection node 120c. In one example, the second section 180b of the fourth beam 180 extending between the third beam intersection node 120c and the fourth beam intersection node 120d, the second section 180b and third section 180c of the fourth beam 180 located on opposite sides of the fourth beam intersection node 120d.

[0080] The second section 160b of the second beam 160 extends between the first intersection node 120a and the third intersection node 120c. In one example, the second beam 160 further includes a third section 160c. The second section 160b and third section 160c of the second beam 160 are located on opposite sides of the second intersection node 120b. In one example, the transverse width W160b of the second section 160b of the second beam 160 increases with axial distance from the third intersection node 120c and the transverse width W160c of the third section 160c of the second beam 160 increases with axial distance from the third intersection node 120c. Further, the transverse width W180a of the first section 180a of the fourth beam 180 increases with axial distance from the third intersection node 120c and the transverse width W180b of the second section 180b of the fourth beam 180 increases with axial distance from the third intersection node 120c. In one example, the transverse width W160b of the second section 160b of the second beam 160 decreases with axial distance from the fourth intersection node 120d, the transverse width W160c of the third section 160c of the second beam 160 decreases with axial distance from the fourth intersection node 120d, the transverse width W180b of the second section 180b of the fourth beam 180 decreases with axial distance from the fourth intersection node 120d, and the transverse width W180c of the third section 180c of the fourth beam 180 decreases with axial distance from the fourth intersection node 120d.

[0081] In one or more examples, each of the beam intersection nodes 120a, 120b, 120c, and 120d extends along a node axis AN that is orthogonal to the longitudinal beam axis AL. The first beam intersection node 120a has a first transverse cross-sectional area and the second beam intersection node 120b has a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0082] In one or more examples, the first transverse cross-sectional area is defined by a first reference quadrilateral 190 having corner points 190a, 190b, 190c, 190d defined by intersection points of the side surfaces of the first beam 150 and second beam 160 and wherein the second transverse cross-sectional area is defined by a second reference quadrilateral 192 having corner points 192a, 192b, 192c, 192d defined by intersection points of the side surfaces of the first beam 150 and third beam 170.

[0083] In one or more examples, the first beam intersection node 120a comprises a first type of hanger assembly 130. In one example, the first type of hanger assembly 130 comprises a plug assembly 132 comprising a first mounting plate 134 embedded in the plug 132 and configured to be coupled to a first hanger 136 to hang the lattice 100 from an overhead support structure 12.

[0084] In one or more examples, the second beam intersection node 120b comprises a second type of hanger assembly 140 that is different than the first type of hanger assembly 130. In one example, the second type of hanger assembly 140 comprises a second mounting plate 142 coupled to the tops 103 of the third beam 170 and configured to be coupled to a second hanger 144 to hang the lattice 100 from the overhead support structure 12.

[0085] In one or more examples, each of the plurality of beams 102 of the ceiling system 10 is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams 102 is a hollow beam structure formed by one or more folded sheets of material.

[0086] In one or more examples, each of the plurality of beams 102 comprises a transverse height H measured from the bottom 101 to the top 103. In one example, the transverse height H of the at least one of the plurality of beams 102 varies along the longitudinal beam axis AL for at least the section of the at least one of the plurality of beams 102.

[0087] The ceiling system 10 may be defined by a plurality of beams 102, each of the beams 102 extending along a longitudinal beam axis AL L from a first end 102a to a second end 102b and comprising a plurality of sections. In one example, each of the plurality of sections has a transverse width W that varies with distance from the first end 102a and a transverse height H that varies with distance from the first end 102a. In another example, the beams 102 are arranged in an intersecting manner to form a lattice 100 comprising a plurality of beam intersection nodes 120.

[0088] In one example, for each of the plurality of sections of each of the plurality of beams 102, as the transverse width W increases, the transverse height H decreases. In another example, for each of the plurality of sections of each of the plurality of beams 102, as the transverse width W increases, the transverse height H increases.

[0089] In one example, for each of the plurality of beams 102, the plurality of sections comprises tapering sections and widening sections arranged in an alternating manner along the longitudinal beam axis AL. The transverse width W of each of the tapering sections may decrease with axial distance from the first end 102a, and the transverse width W of each of the widening sections may increase with axial distance from the first end 102a.

[0090] In one example, for each of the plurality of beams 102, the transverse height H each of the tapering sections increases with axial distance from the first end 102a, and the transverse height H of each of the widening sections decreases with axial distance from the first end 102a.

[0091] In one example, for each of the plurality of beams 102, the transverse height H each of the tapering sections decreases with axial distance from the first end 102a, and the transverse height H of each of the widening sections increases with axial distance from the first end 102a.

[0092] In one example, each of the plurality of beams 102 is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams 102 is a hollow beam structure formed by one or more folded sheets of material.

[0093] In one example, the plurality of beam intersection nodes 120 comprises a plurality of first beam intersection nodes 120a having a first transverse cross-sectional area and a plurality of second beam intersection nodes 120b having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0094] In one example, each of the first and second transverse cross-sectional areas is defined by a reference quadrilateral 190 having corner points defined by intersection points of side surfaces of the plurality of beams 102.

[0095] In one example, each of the first beam intersection nodes 120a comprises a first type of hanger assembly 130. In one example, each of the first type of hanger assemblies 130 comprises a plug assembly 132 comprising a first mounting plate 134 embedded in the plug and configured to be coupled to a first hanger 136 to hang the lattice 100 from an overhead support structure 12.

[0096] In one example, each of the second beam 160 intersection nodes 120 comprises a second type of hanger assembly 140 that is different than the first type of hanger assembly 130. In one example, each of the second type of hanger assemblies 140 comprises a second mounting plate 142 coupled to tops of the beam and configured to be coupled to a second hanger 144 to hang the lattice 100 from the support structure 12.

[0097] In one or more examples, the ceiling system 10 includes a plurality of beams 102, each of the beams 102 extending along a longitudinal beam axis AL from a first end 102a to a second end 102b. The plurality of beams 102 may be arranged in an intersecting manner to form a lattice 100 comprising at least two different types of beam intersection nodes 120a, 120b.

[0098] In one or more examples, the at least two different types of beam intersection nodes 120a, 120b comprises at least one first beam intersection node 120a and at least one second beam intersection node 120b. In one example, the at least one first beam intersection node 120a comprises a first transverse cross-sectional area and the at least one second beam intersection node 120b comprises a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0099] In another example, the at least two different types of beam intersection nodes 120 comprise at least one first beam intersection node 120a and at least one second beam intersection node 120b. The at least one first beam intersection node 120a comprises a first type of hanger assembly 130 and the at least second beam intersection node 120b comprises a second type of hanger assembly 140 that is different than the first type of hanger assembly 130.In one example, the first type of hanger assembly 130 comprises a plug assembly 132 comprising a first mounting plate 134 embedded in the plug and configured to be coupled to a first hanger 136 to hang the lattice 100 from an overhead support structure 12, and the second type of hanger 140 comprises a second mounting plate 142 coupled to the tops of the third beam 170 and configured to be coupled to a second hanger 144 to hang the lattice 100 from the overhead support structure 12.

[0100] In one or more examples, each of the plurality of beams 102 is formed of an acoustic material. In one example, the acoustic material is felt. In one example, each of the plurality of beams 102 is a hollow beam structure formed by one or more folded sheets of material.

[0101] Also disclosed is an acoustic ceiling beam 102. In one example, the acoustic ceiling beam 102 includes a first end 102a, a second end 102b, a longitudinal beam axis AL extending from the first end 102a to the second end 102b, and a plurality of tapering sections. Each of the tapering sections has a transverse width W that decreases with axial distance from the first end 102a, a plurality of widening sections, and each of the widening sections having a transverse width W that increases with axial distance from the first end 102a. In one example, the tapering sections and the widening sections are arranged in an alternating manner along the longitudinal beam axis AL. In another example, the acoustic ceiling beam is formed of an acoustic material.

[0102] In one example, transverse height H each of the tapering sections increases with axial distance from the first end 102a, and the transverse height H of each of the widening sections decreases with axial distance from the first end 102a.

[0103] In one or more examples, each of the tapering sections decreases with axial distance from the first end 102a, and the transverse height H of each of the widening sections increases with axial distance and the first end 102a.

[0104] In one example, the acoustic material is felt. In another example, the acoustical ceiling beam 102 is a hollow beam structure formed by one or more folded sheets of material.

[0105] Referring to FIG. 9 and FIG. 10, in one or more examples, each of the plurality of beams 102 may abut a frame 111. The frame 111 may cover every end 102a and 102b of each of the plurality of beams 102 forming the lattice 100. In one example, the frame 111 is comprised of a single, monolithic structure. In another example, the frame 111 is comprised of two or more structures coupled together. The frame 111 may be comprised of the same material, such as a felt material, as each of the plurality of beams 102.

[0106] Referring to FIGS. 11 and 12, the lattice 100 may include a plurality of beams 102 having more than four beams. The lattice 100 may have any number of a plurality of beams 102, including 6, 7, 8, 9, 10, or more beams.

[0107] The disclosed may be characterized by the following Exemplary Claims.

[0108] Exemplary Claim 1. A ceiling system comprising: a plurality of beams arranged in an intersecting manner to form a lattice, the plurality of beams intersecting one another at beam intersection nodes, each of the plurality of beams extending along a longitudinal beam axis from a first end to a second end and comprising: a bottom; a top; a first side surface extending upward from the bottom to the top; a second side surface opposite the first side surface and extending upward from the bottom to the top; and a transverse width measured from the first side surface to the second side surface; and wherein the transverse width of at least one of the plurality of beams varies along the longitudinal beam axis for at least a section of the at least one of the plurality of beams.

[0109] Exemplary Claim 2. The ceiling system according to Exemplary Claim 1 further comprising: the plurality of beams comprising a first beam and a second beam, the first beam intersecting the second beam at a first beam intersection node, the first beam comprising first and second sections located on opposite sides of the first beam intersection node; the transverse width of the first section of the first beam decreasing with axial distance from the first beam intersection node; and the transverse width of the second section of the first beam decreasing with axial distance from the first beam intersection node.

[0110] Exemplary Claim 3. The ceiling system according to Exemplary Claim 2 further comprising: the second beam comprising first and second sections located on opposites sides of the first beam intersection node; the transverse width of the first section of the second beam decreasing with axial distance from the first beam intersection node; and the transverse width of the second section of the second beam decreasing with axial distance from the first beam intersection node.

[0111] Exemplary Claim 4. The ceiling system according to any one of exemplary claims 2 to 3 wherein the second beam extends orthogonal to the first beam.

[0112] Exemplary Claim 5. The ceiling system according to any one of exemplary claims 2 to 4 further comprising: the first section of the first beam having a distal end and the second section of the first beam having a proximal end; the first section of the second beam having a distal end and the second section of the second beam having a proximal end; and each of the distal end of the first section of the first beam, the proximal end of the second section of the first beam, the distal end of the first section of the second beam, and the proximal end of the second section of the second beam comprise engagement features that interlock with one another.

[0113] Exemplary Claim 6. The ceiling system according to any one of exemplary claims 2 to 5 further comprising: the plurality of beams comprising a third beam, the first beam intersecting the third beam at a second beam intersection node that is spaced from the first beam intersection node along the first beam, the second section of the first beam extending between the first beam intersection node and the second beam intersection node, the first beam further comprising a third section, the second and third sections of the first beam located on opposite sides of the second beam intersection node; the transverse width of the second section of the first beam increasing with axial distance from the second beam intersection node; and the transverse width of the third section of the first beam increasing with axial distance from the second beam intersection node.

[0114] Exemplary Claim 7. The ceiling system according to Exemplary Claim 6 further comprising: the third beam comprising first and second sections located on opposites sides of the second beam intersection node; the transverse width of the first section of the third beam increasing with axial distance from the second beam intersection node; and the transverse width of the second section of the second beam increasing with axial distance from the first beam intersection node.

[0115] Exemplary Claim 8. The ceiling system according to any one of exemplary claims 6 to 7 wherein the third beam extends parallel to the second beam.

[0116] Exemplary Claim 9. The ceiling system according to any one of exemplary claims 6 to 8 further comprising: the plurality of beams comprising a fourth beam comprising a first section, a second section, and a third section; the fourth beam intersecting the second beam at a third intersection node that is spaced from the first intersection node along the second beam; the fourth beam intersecting the third beam at a fourth beam intersection node that is spaced from the third beam intersection node along the fourth beam, the fourth beam intersection node spaced from the second beam intersection node along the third beam; the first and second sections of the fourth beam located on opposite sides of the third beam intersection node, the second section of the fourth beam extending between the third beam intersection node and the fourth beam intersection node, the second and third sections of the fourth beam located on opposite sides of the fourth beam intersection node; the second section of the second beam extending between the first intersection node and the third intersection node, the second beam further comprising a third section, the second and third sections of the second beam located on opposite sides of the second intersection node; the transverse width of the second section of the second beam increasing with axial distance from the third intersection node; the transverse width of the third section of the second beam increasing with axial distance from the third intersection node; the transverse width of the first section of the fourth beam increasing with axial distance from the third intersection node; the transverse width of the second section of the fourth beam increasing with axial distance from the third intersection node; the transverse width of the second section of the second beam decreasing with axial distance from the fourth intersection node; the transverse width of the third section of the second beam decreasing with axial distance from the fourth intersection node; the transverse width of the second section of the fourth beam decreasing with axial distance from the fourth intersection node; and the transverse width of the third section of the fourth beam decreasing with axial distance from the fourth intersection node.

[0117] Exemplary Claim 10. The ceiling system according to any one of exemplary claims 6 to 9 further comprising: each of the beam intersection nodes extending along a node axis that is orthogonal to the beam axes; the first beam intersection node having a first transverse cross-sectional area; and the second beam intersection node having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0118] Exemplary Claim 11. The ceiling system according to Exemplary Claim 10 wherein the first transverse cross-sectional area is defined by a first reference quadrilateral having corner points defined by intersection points of the side surfaces of the first and second beams and wherein the second transverse cross-sectional area is defined by a second reference quadrilateral having corner points defined by intersection points of the side surfaces of the first and third beams.

[0119] Exemplary Claim 12. The ceiling system according to any one of exemplary claims 6 to 11 further comprising: the first beam intersection node comprising a first type of hanger assembly; and the second beam intersection node comprising a second type of hanger assembly that is different than the first type of hanger assembly.

[0120] Exemplary Claim 13. The ceiling system according to Exemplary Claim 12 wherein the first type of hanger assembly comprises a plug assembly comprising a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly comprises a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.

[0121] Exemplary Claim 14. The ceiling system according to any one of exemplary claims 1 to 13 wherein each of the plurality of beams is formed of an acoustic material.

[0122] Exemplary Claim 15. The ceiling system according to Exemplary Claim 14 wherein the acoustic material is felt.

[0123] Exemplary Claim 16. The ceiling system according to any one of exemplary claims 1 to 15 wherein each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0124] Exemplary Claim 17. The ceiling system according to any one of exemplary claims 1 to 16 wherein each of the plurality of beams comprises a transverse height measured from the bottom to the top; and wherein the transverse height of the at least one of the plurality of beams varies along the longitudinal beam axis for at least the section of the at least one of the plurality of beams.

[0125] Exemplary Claim 18. A ceiling system comprising: a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end and comprising a plurality of sections, each of the plurality of sections having a transverse width that varies with distance from the first end and a transverse height that varies with distance from the first end; and the beams arranged in an intersecting manner to form a lattice comprising a plurality of beam intersection nodes.

[0126] Exemplary Claim 19. The ceiling system according to Exemplary Claim 18 wherein for each of the plurality of sections of each of the plurality of beams, as the transverse width increases, the transverse height decreases.

[0127] Exemplary Claim 20. The ceiling system according to any one of exemplary claims 18 to 19 wherein, for each of the plurality of beams, the plurality of sections comprise tapering sections and widening sections arranged in an alternating manner along the beam axis, the transverse width of each of the tapering sections decreasing with axial distance from the first end, and the transverse width of each of the widening sections increasing with axial distance from the first end.

[0128] Exemplary Claim 21. The ceiling system according to Exemplary Claim 20 wherein, for each of the plurality of beams, the transverse height each of the tapering sections increases with axial distance from the first end, and the transverse height of each of the widening sections decreases with axial distance from the first end.

[0129] Exemplary Claim 22. The ceiling system according to Exemplary Claim 20 wherein, for each of the plurality of beams, the transverse height each of the tapering sections decreases with axial distance from the first end, and the transverse height of each of the widening sections increases with axial distance from the first end.

[0130] Exemplary Claim 23. The ceiling system according to any one of exemplary claims 18 to 22 wherein each of the plurality of beams is formed of an acoustic material.

[0131] Exemplary Claim 24. The ceiling system according to Exemplary Claim 23 wherein the acoustic material is felt.

[0132] Exemplary Claim 25. The ceiling system according to any one of exemplary claims 18 to 24 wherein each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0133] Exemplary Claim 26. The ceiling system according to any one of exemplary claims 18 to 25 wherein the plurality of beam intersection nodes comprises a plurality of first beam intersection nodes having a first transverse cross-sectional area and a plurality of second beam intersection nodes having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0134] Exemplary Claim 27. The ceiling system according to Exemplary Claim 26 wherein each of the first and second transverse cross-sectional areas is defined by a reference quadrilateral having corner points defined by intersection points of side surfaces of the plurality of beams.

[0135] Exemplary Claim 28. The ceiling system according to any one of exemplary claims 26 to 27 further comprising: each of the first beam intersection nodes comprising a first type of hanger assembly; and each of the second beam intersection nodes comprising a second type of hanger assembly that is different than the first type of hanger assembly.

[0136] Exemplary Claim 29. The ceiling system according to Exemplary Claim 28 wherein each of the first type of hanger assemblies comprises a plug assembly comprising a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein each of the second type of hanger assemblies comprises a second mounting plate coupled to tops of the beam and configured to be coupled to a second hanger to hang the lattice from the support structure.

[0137] Exemplary Claim 30. A ceiling system comprising: a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end; and the beams arranged in an intersecting manner to form a lattice comprising at least two different types of beam intersection nodes.

[0138] Exemplary Claim 31. The ceiling system according to Exemplary Claim 30 wherein the at least two different types of beam intersection nodes comprises at least one first beam intersection node and at least one second beam intersection node; and wherein the at least one first beam intersection node comprises a first transverse cross-sectional area and the at least one second beam intersection node comprises a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

[0139] Exemplary Claim 31. The ceiling system according to any one of exemplary claims 30 wherein the at least two different types of beam intersection nodes comprises at least one first beam intersection node and at least one second beam intersection node; and the at least one first beam intersection node comprises a first type of hanger assembly and the at least second beam intersection node comprises a second type of hanger assembly that is different than the first type of hanger assembly.

[0140] Exemplary Claim 32. The ceiling system according to Exemplary Claim 31 wherein the first type of hanger assembly comprises a plug assembly comprising a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly comprises a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.

[0141] Exemplary Claim 33. The ceiling system according to any one of exemplary claims 30 to 32 wherein each of the plurality of beams is formed of an acoustic material.

[0142] Exemplary Claim 34. The ceiling system according to Exemplary Claim 14 wherein the acoustic material is felt.

[0143] Exemplary Claim 35. The ceiling system according to any one of exemplary claims 30 to 34 wherein each of the plurality of beams is a hollow beam structure formed by one or more folded sheets of material.

[0144] Exemplary Claim 37. An acoustic ceiling beam comprising: a first end; a second end; a beam axis extending from the first end to the second end; a plurality of tapering sections, each of the tapering sections having a transverse width that decreases with axial distance from the first end; a plurality of widening section, each of the widening sections having a transverse width that increases with axial distance from the first end; the tapering sections and the widening sections arranged in an alternating manner along the beam axis; and wherein the acoustic ceiling beam is formed of an acoustic material.

[0145] Exemplary Claim 38. The acoustic ceiling beam according to Exemplary Claim 37 wherein the transverse height each of the tapering sections increases with axial distance from the first end, and the transverse height of each of the widening sections decreases with axial distance from the first end.

[0146] Exemplary Claim 38. The acoustic ceiling beam according to Exemplary Claim 37 wherein each of the tapering sections decreases with axial distance from the first end, and the transverse height of each of the widening sections increases with axial distance from the first end.

[0147] Exemplary Claim 39. The acoustic ceiling beam according to Exemplary Claim 37 wherein the acoustic material is felt.

[0148] Exemplary Claim 40. The acoustic ceiling beam according to any one of exemplary claims 37 to 39 wherein the acoustical ceiling beams is a hollow beam structure formed by one or more folded sheets of material.

[0149] While the present disclosure has been described with reference to several examples, which examples have been set forth in considerable detail for the purposes of making a complete disclosure of the disclosure, such examples are merely representative and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the disclosure. The scope of the disclosure is to be determined from the claims appended hereto. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the disclosure.

Examples

Embodiment Construction

[0053]For illustrative purposes, the principles of the present disclosure are described by referencing various examples thereof. Although certain examples of the disclosure are specifically described herein, one of ordinary skill in the art will readily recognize that the same principles are equally applicable to, and can be employed in other applications and methods. It is to be understood that the disclosure is not limited in its application to the details of any particular example shown. The terminology used herein is for the purpose of description and not to limit the disclosure, its application, or uses.

[0054]As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context dictates otherwise. The singular form of any class of the ingredients refers not only to one chemical species within that class, but also to a mixture of those chemical species. The terms “a” (or “an”), “one or more” and “at least one” may be used...

Claims

1. A ceiling system comprising:a plurality of beams arranged in an intersecting manner to form a lattice, the plurality of beams intersecting one another at beam intersection nodes, each of the plurality of beams extending along a longitudinal beam axis from a first end to a second end and comprising:a bottom;a top;a first side surface extending upward from the bottom to the top;a second side surface opposite the first side surface and extending upward from the bottom to the top; anda transverse width measured from the first side surface to the second side surface; andwherein the transverse width of at least one of the plurality of beams varies along the longitudinal beam axis for at least a section of the at least one of the plurality of beams.

2. The ceiling system according to claim 1 further comprising:the plurality of beams comprising a first beam and a second beam, the first beam intersecting the second beam at a first beam intersection node, the first beam comprising first and second sections located on opposite sides of the first beam intersection node;the transverse width of the first section of the first beam decreasing with axial distance from the first beam intersection node; andthe transverse width of the second section of the first beam decreasing with axial distance from the first beam intersection node.

3. The ceiling system according to claim 2 further comprising:the second beam comprising first and second sections located on opposites sides of the first beam intersection node;the transverse width of the first section of the second beam decreasing with axial distance from the first beam intersection node; andthe transverse width of the second section of the second beam decreasing with axial distance from the first beam intersection node.

4. (canceled)5. (canceled)6. The ceiling system according to claim 2 further comprising:the plurality of beams comprising a third beam, the first beam intersecting the third beam at a second beam intersection node that is spaced from the first beam intersection node along the first beam, the second section of the first beam extending between the first beam intersection node and the second beam intersection node, the first beam further comprising a third section, the second and third sections of the first beam located on opposite sides of the second beam intersection node;the transverse width of the second section of the first beam increasing with axial distance from the second beam intersection node; andthe transverse width of the third section of the first beam increasing with axial distance from the second beam intersection node.

7. The ceiling system according to claim 6 further comprising:the third beam comprising first and second sections located on opposites sides of the second beam intersection node;the transverse width of the first section of the third beam increasing with axial distance from the second beam intersection node; andthe transverse width of the second section of the second beam increasing with axial distance from the first beam intersection node.

8. (canceled)9. The ceiling system according to claim 6 further comprising:the plurality of beams comprising a fourth beam comprising a first section, a second section, and a third section;the fourth beam intersecting the second beam at a third intersection node that is spaced from the first intersection node along the second beam;the fourth beam intersecting the third beam at a fourth beam intersection node that is spaced from the third beam intersection node along the fourth beam, the fourth beam intersection node spaced from the second beam intersection node along the third beam;the first and second sections of the fourth beam located on opposite sides of the third beam intersection node, the second section of the fourth beam extending between the third beam intersection node and the fourth beam intersection node, the second and third sections of the fourth beam located on opposite sides of the fourth beam intersection node;the second section of the second beam extending between the first intersection node and the third intersection node, the second beam further comprising a third section, the second and third sections of the second beam located on opposite sides of the second intersection node;the transverse width of the second section of the second beam increasing with axial distance from the third intersection node;the transverse width of the third section of the second beam increasing with axial distance from the third intersection node;the transverse width of the first section of the fourth beam increasing with axial distance from the third intersection node;the transverse width of the second section of the fourth beam increasing with axial distance from the third intersection node;the transverse width of the second section of the second beam decreasing with axial distance from the fourth intersection node;the transverse width of the third section of the second beam decreasing with axial distance from the fourth intersection node;the transverse width of the second section of the fourth beam decreasing with axial distance from the fourth intersection node; andthe transverse width of the third section of the fourth beam decreasing with axial distance from the fourth intersection node.

10. The ceiling system according to claim 6 further comprising:each of the beam intersection nodes extending along a node axis that is orthogonal to the beam axes;the first beam intersection node having a first transverse cross-sectional area; andthe second beam intersection node having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

11. (canceled)12. The ceiling system according to claim 6 further comprising:a first type of hanger assembly coupled to at least one of the plurality of beams; anda second type of hanger assembly coupled to at least one of the plurality of beams that is different than the first type of hanger assembly.

13. The ceiling system according to claim 12 wherein the first type of hanger assembly comprises a plug assembly comprising a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly comprises a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.

14. The ceiling system according to claim 1 wherein each of the plurality of beams is formed of an acoustic material.

15. (canceled)16. (canceled)17. The ceiling system according to claim 1 wherein each of the plurality of beams comprises a transverse height measured from the bottom to the top; and wherein the transverse height of the at least one of the plurality of beams varies along the longitudinal beam axis for at least the section of the at least one of the plurality of beams.

18. A ceiling system comprising:a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end and comprising a plurality of sections, each of the plurality of sections having a transverse width that varies with distance from the first end and a transverse height that varies with distance from the first end; andthe beams arranged in an intersecting manner to form a lattice comprising a plurality of beam intersection nodes.

19. The ceiling system according to claim 18 wherein for each of the plurality of sections of each of the plurality of beams, as the transverse width increases, the transverse height decreases.

20. The ceiling system according to claim 18 wherein, for each of the plurality of beams, the plurality of sections comprise tapering sections and widening sections arranged in an alternating manner along the beam axis, the transverse width of each of the tapering sections decreasing with axial distance from the first end, and the transverse width of each of the widening sections increasing with axial distance from the first end.

21. (canceled)22. (canceled)23. The ceiling system according to claim 18 wherein each of the plurality of beams is formed of an acoustic material, and wherein the acoustic material comprises felt.

24. (canceled)25. (canceled)26. The ceiling system according to claim 18 wherein the plurality of beam intersection nodes comprises a plurality of first beam intersection nodes having a first transverse cross-sectional area and a plurality of second beam intersection nodes having a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area, wherein each of the first and second transverse cross-sectional areas is defined by a reference quadrilateral having corner points defined by intersection points of side surfaces of the plurality of beams.27.-29. (canceled)30. A ceiling system comprising:a plurality of beams, each of the beams extending along a longitudinal beam axis from a first end to a second end; andthe beams arranged in an intersecting manner to form a lattice comprising at least two different types of beam intersection nodes.

31. The ceiling system according to claim 30 wherein the at least two different types of beam intersection nodes comprises at least one first beam intersection node and at least one second beam intersection node; and wherein the at least one first beam intersection node comprises a first transverse cross-sectional area and the at least one second beam intersection node comprises a second transverse cross-sectional area that is smaller than the first transverse cross-sectional area.

32. The ceiling system according to claim 30 wherein the at least two different types of beam intersection nodes comprises at least one first beam intersection node and at least one second beam intersection node; and the at least one first beam intersection node comprises a first type of hanger assembly and the at least second beam intersection node comprises a second type of hanger assembly that is different than the first type of hanger assembly.

33. The ceiling system according to claim 32 wherein the first type of hanger assembly comprises a plug assembly comprising a first mounting plate embedded in the plug and configured to be coupled to a first hanger to hang the lattice from an overhead support structure; and wherein the second type of hanger assembly comprises a second mounting plate coupled to the tops of the third beam and configured to be coupled to a second hanger to hang the lattice from the overhead support structure.34.-41. (canceled)

Images