A ceiling panel assembly and method for installing it

Abstract

A ceiling panel assembly (20) comprises a ceiling panel (24); and a plurality of attachment elements (40) for connecting the ceiling panel (24) to a support member (30) of a support structure. Each attachment element (40) includes a slider (42) movable between an installed position (E) where the ceiling panel (24) is connected to the support member (30) and an uninstalled position (R) where the ceiling panel (24) is disconnected from the at least one support member (30). The slider (42) comprises a magnetic element (43) co-operable with a tool (50) comprising a magnetic element (52) for moving the slider (42), in either direction, between the installed position (E) and the uninstalled position (R). Ceiling panels (24) may be installed from beneath simplifying the installation of suspended ceiling systems.

Description

A CEILING PANEL ASSEMBLY AND METHOD FOR INSTALLING ITTECHNICAL FIELD

[0001] The present invention relates to a ceiling panel assembly and method for installing it, for example in a suspended ceiling system. However, the invention is also applicable to other cladding systems.BACKGROUND ART

[0002] The following discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application.

[0003] A cladding system, in particular a ceiling system such as a suspended or dropped ceiling system, is installed by suspending a grid comprising a framework of intersecting support members into which ceiling tiles are inserted, within each opening of the grid, to form the suspended ceiling. Numerous options are available for installation of suspended or dropped ceiling within this framework.

[0004] Installation of a suspended ceiling has proven to be a time consuming process due to difficulties typically faced in preparing ceiling tiles and / or fixing the ceiling tiles to the supporting grid. Some of these methods require working with adhesives and precision work, for example, forming flanges in tiles or using a number of fasteners to fix the ceiling tile to the framework. Further, the fixing typically needs to be discrete for aesthetic purposes and this also requires precision work and much reliance on skill and experience with the associated cost. In some cases, the supporting grid is left exposed, for example as described in US Patent Publication No. 2024117632 and this may be aesthetically undesirable in some applications.

[0005] One fastening arrangement involves fixing ceiling panels to support members using adhesives and screws. This is time consuming, tricky and potentially messy work.

[0006] The present invention has been developed against the above background.SUMMARY OF INVENTION

[0007] In one embodiment, the present invention provides a ceiling panel assembly comprising: a ceiling panel; and an attachment element for connecting the ceiling panel to a support structure, the attachment element including a slider movable between an installed position where the ceiling panel is connected to the support structure and an uninstalled position where the ceiling panel is disconnected from the support structure, wherein the slider comprises a magnetic element co-operable with a tool comprising a magnetic element for moving the slider, in either direction, between the installed position and the uninstalled position by magnetic force.

[0008] In another embodiment, the present invention provides a ceiling system comprising: a support structure comprising at least one support member; and at least one ceiling panel assembly comprising: a ceiling panel; and an attachment element for connecting the ceiling panel assembly to the at least one support member, the attachment element including a slider movable between an installed position where the ceiling panel is connected to the at least one support member and an uninstalled position where the ceiling panel is disconnected from the at least one support member, wherein the slider comprises a magnetic element co-operable with a tool comprising a magnetic element for moving the slider, in either direction, between the installed position and the uninstalled position by magnetic force.

[0009] The slider may be of magnetic material. The magnetic element may be a separate part located within the slider and may have any convenient shape, for example square or circular. The attachment element conveniently comprises a housing foraccommodating the slider. The slider may be captured within the housing by one or more capturing element(s) though it has a permitted lateral movement between the installed and uninstalled positions. In a horizontal direction, the capturing element may include a land or lands having narrower dimension than a rear portion of the slider. However, a dimension between the land and a terminal wall of the housing may be greater than the dimension of the slider allowing a limited range of movement of slider within the housing. In a vertical direction, the housing is preferably configured to prevent any vertical movement of the slider. In one embodiment, the housing may include a plate located to prevent vertical movement of the slider. Use of a plate has the advantage of access to the housing to enable the slider to be replaced if required.

[0010] The slider typically includes a latch portion co-operable with the support structure, typically to the at least one support member, to allow connection of the ceiling panel to the support structure, typically to support members of such support structure. In one embodiment, in an installed position, the latch portion may be fully extended. In another embodiment, the latch portion may be retracted within the housing in an uninstalled position. Such positioning reduces risk of damage to the latch portion. When moved into the installed position, the latch portion engages with the at least one support member, conveniently as described below. Desirably, the latch portion has a downward angle or curvature in a forward direction providing a geometry that assists installation by allowing retraction, for example where necessarily contacting with the support member or a portion of the support member when pressing a ceiling panel into the installed position.

[0011] Desirably, a ferromagnetic part - such as a steel part - may be located at or proximate a base of the housing to attract the slider to a particular position. For example, the ferromagnetic part may be located forward of the base to attract the magnetic element into an extended position which may provide a locked position for installation which may exclude involvement of the tool in a preferred embodiment. The extended position is in one embodiment a default or neutral position, re-attainable following retraction, where necessary during installation, as described above. The magnetic force of attraction may be overcome by a magnetic force generated when the tool is moved in a backward direction towards the uninstalled position.

[0012] The magnetic element of the tool may have the same or opposite polarity to the polarity of the magnetic element of the slider. The mass of the magnetic element of thetool is selected to generate sufficient magnetic energy to overcome inertia of, and enable movement of, the slider when the magnetic element of the slider co-operates with the magnetic element of the tool.

[0013] A plurality of attachment elements may be required for connection of the ceiling panel to the support structure, typically through connection to a plurality of co-operating support members which may form a grid or at least an aperture within a grid. The number of attachment elements is selected with reference to the size and weight of the ceiling panel. Conveniently, the attachment elements are connected at least proximate side edges of the ceiling panel.

[0014] The at least one support member conveniently has configuration as known in the ceiling installation art. In one embodiment of many possible, the at least one support member may have an inverted T shape, for example comprising a horizontally extending bottom flange and an enlarged top stiffening channel connected to the bottom flange by a vertical web. The bottom flange may comprise flange portions respectively disposed on each side of the vertical web. The slider or latch portion thereof in preferred embodiments, when in installed position, is seated on the bottom flange or a bottom flange portion to support, in co-operation with further attachment elements, the ceiling panel.

[0015] The ceiling system is conveniently a suspended ceiling system. In such an embodiment, the present invention may comprise a method for installing a ceiling panel comprising the steps of: connecting to a ceiling panel a plurality of attachment elements, each attachment element including a slider movable between an installed position where the ceiling panel is connected to co-operating support members of a support structure and an uninstalled position where the ceiling panel is disconnected from the co-operating support members, the slider comprising a magnetic element; and connecting the ceiling panel to a support member of a support structure by moving the slider of each attachment element from an uninstalled position to an installed position in which the slider co-operates with a co-operating support member to connect the ceiling panel to the support structure,wherein the slider is movable in either direction between the uninstalled position and the installed position by co-operation of the magnetic element of the slider with a magnetic element of a tool which is conveniently separated from the slider by the ceiling panel.

[0016] The ceiling panel assembly and installation method using the above described attachment element avoid working with adhesives and precision work, for example, forming flanges in tiles or using a number of fasteners to fix the ceiling tile to the framework all of which typically involve working under time pressure. At the same time, the ceiling panel assembly and installation method enable installation of a suspended ceiling system, for example, from underneath, which is easier, while concealing the supporting grid.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Further features of the ceiling panel assembly and method of installation of the present invention are more fully described in the following description of several nonlimiting embodiments thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:

[0018] Figure 1 is a schematic side view of a ceiling panel assembly in installed position connected to a supporting structure by an attachment element having a slider operable by a magnetic tool according to one embodiment of the present invention.

[0019] Figure 2 is a schematic side view of a ceiling panel assembly in uninstalled position prior to connection to a supporting structure as shown in Figure 1.

[0020] Figure 3 is an exploded view of the attachment element of Figures 1 and 2 also showing the magnetic tool.

[0021] Figure 4 is a front view of the attachment element of Figures 1 to 3.

[0022] Figure 5 is a top view of the attachment element of Figures 1 to 4.

[0023] Figure 6 is a rear view of the attachment element of Figures 1 to 5.

[0024] Figure 7 is a side view of the attachment element of Figures 1 to 6.

[0025] Figure 8 is a bottom view of the attachment element of Figures 1 to 7.

[0026] Figure 9 is a schematic isometric view showing the relationship between attachment element and magnetic tool with the ceiling panel omitted for purposes of illustration.

[0027] Figure 10 is a schematic side view a ceiling panel assembly in installed position connected to a supporting structure by an attachment element as shown in Figure 1.

[0028] Figure 11 is a detail top view of the ceiling panel assembly of Figures 1 and 2.

[0029] Figure 12 is an isometric view of the ceiling panel assembly of Figures 1 , 2 and 11.DESCRIPTION OF PREFERRED EMBODIMENTS

[0030] Referring to Figures 1 and 2, there is shown portion of a ceiling system 10 in which a ceiling panel assembly 20 is connected to a support member 30 of a support structure in the form of a supporting framework or grid (not shown) made up of a number of co-operating support members 30 which is suspended from an overhead building support structure, such as a floor, in a manner known in the art of ceiling installation. Ceiling system 10 comprises a plurality of ceiling panel assemblies 20 and may be installed in an interior space such as a room of a building.

[0031] The supporting grid includes a framework of co-operating through intersecting lateral and longitudinal support members, each being the same or similar to support member 30 and spaced apart at determined intervals to provide a plurality of grid openings which are closed by ceiling panels such as ceiling panel 24. As shown, the supporting grid is horizontally suspended. The support members 30 are of any suitable metallic or non-metallic material with the required structural characteristics - for example steel, aluminium or titanium - which can support the weight of ceiling panels 24. While support members 30 may be ferro magnetic, this is not a requirement. Support members 30 could be of timber or other suitable non-ferromagnetic structural materials.

[0032] Ceiling panel assembly 20 comprises a ceiling panel 24 and an attachment element or locking pin 40 for fixing the ceiling panel assembly 20 to support member 30. Ceiling panel 24 is connected to the support member 30 by the locking pin 40, one ofwhich is shown for ease of illustration and an embodiment of which is described in further detail below. A plurality of locking pins 40 would typically be necessary for complete connection of ceiling panel 24 to support member 30 and the locking pinsupport member connection step may be repeated as many times as is necessary.

[0033] Referring also to Figures 3 to 12, locking pin 40 comprises a housing 41, for example of diecast aluminium though a range of other suitable materials are available typically being rigid and durable to allow connection and maintenance of connection between locking pin 40 and support member 30. Housing 41 accommodates a mobile slider 42, which is generally rectangular in shape and captured within the housing 41. Slider 42 may be considered a pin, latch or bolt co-operable with the support member 30 to allow connection of the ceiling panel 24 to the support member 30 and supporting grid. In an embodiment, slider 42 has a latch portion 42a which has lesser width than a rear portion of the slider. Slider 42 may be slid from a retracted position in which latch portion 42a is retracted within the housing 41 (useful to protect the latch portion 42a from damage) to an extended position in which the latch portion 42a extends through a forward rectangular opening 49 of housing 41.

[0034] Latch portion 42a has a downward angle or curvature in a forward direction providing a geometry that assists installation of ceiling panel 24 as described below.

[0035] Slider 42 comprises a magnetic element 43 which may be a magnet selected, for example, from the group consisting of an alnico magnet, a ferrite magnet, a ceramic magnet, a neodymium iron boron magnet and a samarium cobalt or other rare earth containing magnet. The magnetic element 43 may be accommodated in or located within, for example by moulding, into the slider 42. In the embodiment shown, the magnetic element 43 is accommodated in recess 42c of the slider 42. The magnetic element 43 may have any convenient shape, for example square or circular, in this embodiment circular, depending on ease of procurement of magnetic elements of desired geometry. The geometry of magnetic element 43 should not interfere with its function as described below. In an alternative embodiment, slider 42 may be made of a magnetic material such as those exemplified above.

[0036] Slider 42 is accommodated in the housing 41 such that it has a permitted lateral movement between an extended position E (corresponding with an installed position as shown in Figure 1) and retracted or uninstalled position R as shown in Figure 2. In a horizontal direction, the rear portion 42c of slider 42 is captured by a pair of capturingelements, as shown lands 41a, to form a passage 49a having narrower dimension than the width of a terminal wall 44 of the housing 41. A dimension D between the lands 41a and the terminal wall 44 of the housing 41 is slightly greater, by about 5-10mm, than the length of the slider 42 allowing it a limited range of movement within the housing 41. Slider 42 may be provided on each longitudinally extending side of rear portion 42c with horizontally extending ribs 42b located in corresponding channels (not shown) in housing 41 to guide movement of slider 42.

[0037] In a vertical direction, the housing 41 includes a plate 47, secured to the housing 41 by screws 48 located through bolt holes 47a, to prevent vertical movement of the slider 42. Screws 48 may be replaced by other suitable fasteners. Plate 47 may be removed to enable replacement of slider 42 or magnetic element 43. In this regard, housing 41 could be configured to accommodate sliders 42 of different dimensions suitable for similar applications but allowing for variability in the type of ceiling panel and support structure.

[0038] A base 45 of housing 41 is provided with a plurality of spaced screws 41b to allow connection to ceiling panel 24. Also provided forward of the base 45 is a steel part 46 which is magnetically attracted to magnetic element 43 and thus biasing the slider 42 into an extended position in a preferred embodiment.

[0039] In an uninstalled position, as shown, the slider 42 has the default or neutral extended position. However, in other embodiments, slider 42 may be fully accommodated or retracted within the housing 41 prior to installation of ceiling panel 24. Such positioning would reduce risk of damage to the slider 42. When moved into the installed position, as described below, the latch portion 42a of slider 42 extends through forward opening 49 and beyond the housing 41 to engage with the at least one support member 30 with a view to a durably secure connection. The magnetic attraction between magnetic element 43 and steel part 46 assists locking of the slider 42 into the installed position. For example, attraction between the steel part 46 and the magnetic element 43 facilitates achievement of a locked position for slider 42 on installation.

[0040] The magnetic tool 50, co-operable with locking pin 40, may be configured in a range of ways. The magnetic tool 50 comprises a magnetic element 52 which may be of the same kind as used for magnetic element 43. However, the magnetic element 52 may have opposite polarity to magnetic element 43 such that the magnetic elements are attracted, by magnetic force, toward each other. The mass of the magnetic element 52is selected to generate sufficient magnetic energy to overcome inertia of, and enable movement of, the slider 42 from an installed to an uninstalled position when the magnetic element 52 of the tool 50 co-operates with the magnetic element 43 of the locking pin 40 as described below.

[0041] The tool 50 is conveniently has cylindrical shape but it will be appreciated that the shape is of no particular functional significance though ergonomic features, such as a grip may be included if desired. Desirably, the magnetic tool 50 is relatively light weight so that its use during installation of ceiling panel 24, as described below, is easy.

[0042] Ceiling panel 24 may be planar and rectilinear, being in the form of a square or rectangle of various dimensions as typically commercially available for suspended ceilings. However, ceiling panels of other geometries could be employed with the supporting grid being configured to suit the selected geometry. Ceiling panel 24 may be fabricated from a range of materials as known in the art of suspended ceilings. Preferably, ceiling panel 24 is formed of timber. Other suitable materials for ceiling panel 24 include, without limitation, fibreglass, fibreboard, metals, metal composites, polymers, polymer-metal composites and so on. Ceiling panels 24 may be acoustic panels for sound absorption.

[0043] In view of the use of locking pins 40 for connection, there is no need to form steps, to provide load bearing flanges, in ceiling panel 24 as would be typical for prior suspended ceiling systems.

[0044] Ceiling panel 24 is connected to support member 30 and adjacent support members (not shown) at its peripheral edges by locking pins 40. A plurality of locking pins 40 are connected, for example by screws 41b though any suitable fastener may be used, close to opposed peripheral edges 25 of the ceiling panel 24 as shown in Figure 12. Connection of locking pins 40 to ceiling panel 24 may be done away from the worksite or at ground level at the work site, either being convenient in comparison to making such connection at a height. Use of adhesives is avoided in preferred embodiments.

[0045] Support member 30, as with other support members within the supporting grid, has an inverted T shape in the embodiment shown. Support member 30 has a horizontally extending bottom flange 32 and an enlarged top stiffening channel 34 connected to bottom flange 32 by vertical web 33 in the embodiment shown. Bottomflange 32 comprises flange portions 32a and 32b respectively disposed on each side of the vertical web 33. Flange portions 32a and 32b conveniently have the same width. On installation of ceiling panels 24, as described below, no portion of bottom flange 32 is visible from the space below the supporting grid. Flange portions 32a and 32b support the locking pin 40 when the ceiling panels 24 are in an installed position with ceiling panel sides 24a of adjacent ceiling panels 24 directly abutting and overlapping with the flange portions 32a and 32b. In this way, air leaks and acoustic deficiencies may be avoided though acoustic sealing materials - such as gaskets - may be used if required.

[0046] Installing ceiling panel 24 proceeds from beneath the supporting grid as follows. A plurality of locking pins 40 are connected to the ceiling panel 24. The number of locking pins 40 to be connected depend on the size and weight of the ceiling panel 24. Two to three locking pins 40 may be connected to each opposed peripheral edge 25 of the ceiling panel 24 in some embodiments. Location and number of the locking pins 40 may be determined with reference to the weight of ceiling panel 24.

[0047] Locking pin 40 has construction as described above.

[0048] One side 24a of the ceiling panel 24 is pressed - working from beneath ceiling panel 24 and supporting grid as indicated in Figures 1 and 2 - against bottom flange portion 32a of support member 30.

[0049] The ceiling panel 24 is connected to the support member 30 by sliding, in this embodiment, the extended latch portions 42a of sliders 42 of each locking pin 40 over the bottom web portion 32a from an uninstalled position R to the installed position E as indicated by comparison between Figures 1 and 2. During this step, latch portions 24a may retract slightly, and temporarily, on contacting bottom web portions 32a easing movement over bottom web portions 32a. The downward angle or curvature of latch portions 24a assists this. Once the initial resistance of bottom web portions 32a to the slider 42 is overcome, the latch portions 24a spring back into default extended or installed position supported by bottom web portions 32a due to the attraction of magnetic element 43 to steel part 46 and without involvement of tool 50. The installation is then complete.

[0050] Sliding of the latch portion 42a of a slider 42 of locking pin 40 from uninstalled position to installed position could, in other embodiments, be accomplished by use ofthe magnetic tool 50. In such embodiments, the installer moves magnetic tool 50 into close proximity with bottom portion 24b of ceiling panel 24. Bottom portion 42b is desirably located immediately below the locking pin 40 though on the opposite side of the ceiling panel 24. In one embodiment, the magnetic element 43 of the locking pin 40 has opposite polarity to magnetic element 52 of magnetic tool 50. That is the magnetic elements 43 and 52 are attracted to each other by a magnetic force sufficient to move the slider 42 as the magnetic tool 50 is moved in a direction toward the supporting member 30 for installation. In this embodiment, attraction between magnetic element 43 and steel part 46 may help to lock slider 42 and latch portion 42a into installed position. It is not necessary that the latch portion 42a magnetically co-operate with, e.g. by being magnetically attracted to, the supporting member 30 or its bottom flange 32.

[0051] If removal of a ceiling panel 24 is required, the latch portion 42a overlaps bottom flange portion 32a in a starting installed position E. The latch portion 42a is then moved to the uninstalled position by moving the magnetic tool 50 along the surface of bottom portion 24b in a direction away from the supporting member 30. The magnetic force of attraction between magnetic element 43 and steel part 46 is overcome by the magnetic force generated when the tool 50 and its magnetic element 52 is moved in a backward direction towards the uninstalled position R.

[0052] The ceiling panel assembly and installation method using the above-described attachment element avoid working with adhesives and precision work, for example, forming flanges in tiles or using a number of fasteners to fix the ceiling tile to the framework all of which typically involve working under time pressure. At the same time, the ceiling panel assembly and installation method enable installation from underneath, which is easier, while concealing the supporting grid. This is especially beneficial for suspended ceiling systems.

[0053] Modifications and variations to the ceiling panel assembly and method of installation described in this specification may be apparent to skilled readers. Such modifications and variations form part of the present invention. For example, though the above description is of a ceiling system it will be understood that the principles could be applied to other cladding systems.

[0054] Throughout this specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of anyother integer or group of integers

Claims

CLAIMS1. A ceiling panel assembly comprising: a ceiling panel; and an attachment element for connecting the ceiling panel to a support structure, the attachment element including a slider movable between an installed position where the ceiling panel is connected to the support structure and an uninstalled position where the ceiling panel is disconnected from the support structure, wherein the slider comprises a magnetic element co-operable with a tool comprising a magnetic element for moving the slider, in either direction, between the installed position and the uninstalled position.

2. The ceiling panel assembly of claim 1 , wherein the attachment element comprises a housing for accommodating the slider; at least one capturing element for capturing the slider within the housing while providing the slider with a permitted lateral movement between the installed and uninstalled positions; and a plate located to prevent vertical movement of the slider.

3. The ceiling panel assembly of claim 1 or 2, wherein the slider includes a latch portion co-operable with the support structure.

4. The ceiling panel assembly of claim 3, wherein the latch portion is fully retracted within the housing in an uninstalled position.

5. The ceiling panel assembly of claim 3 or 4, wherein the latch portion has a downward angle of curvature in a forward direction.

6. The ceiling panel assembly of any one of the preceding claims, wherein a ferromagnetic part is located at or proximate a base of the housing to attract the magnetic element into an extended position.

7. The ceiling panel assembly of claim 6, wherein the extended position provides a locked position for installation.

8. The ceiling panel assembly of claim 7, wherein the extended position provides a locked position for installation without involvement of the tool.

9. The ceiling panel assembly of any one of claims 6 to 8, wherein the extended position is a default or neutral position.

10. The ceiling panel assembly of any one of the preceding claims, wherein the ceiling panel comprises a plurality of attachment elements, each attachment element being connected at least proximate side edges of the ceiling panel.

11. The ceiling panel assembly of any one of the preceding claims, comprising connection between the ceiling panel and at least one support member of the support structure.

12. The ceiling panel assembly of claim 11, as dependent from claim 3, wherein the at least one support member has an inverted T-shape comprising a horizontally extending bottom flange; and an enlarged top stiffening channel connected to the bottom flange by a vertical web, wherein the bottom flange comprises flange portions respectively disposed on each side of the vertical web and the latch portion of the slider is seated on a bottom flange portion to support the ceiling panel.

13. The ceiling panel of any one of the preceding claims, wherein the slider is of magnetic material.

14. A ceiling system comprising: a support structure comprising at least one support member; and at least one ceiling panel assembly comprising: a ceiling panel; and an attachment element for connecting the ceiling panel assembly to the at least one support member, the attachment element including a slider movable between an installed position where the ceiling panel is connected to the at least one support member and an uninstalled position where the ceiling panel is disconnected from the at least one support member,wherein the slider comprises a magnetic element co-operable with a tool comprising a magnetic element for moving the slider, in either direction, between the installed position and the uninstalled position by magnetic force.

15. The ceiling system of claim 14, being a suspended ceiling system.

16. A method for installing a ceiling panel comprising the steps of: connecting to a ceiling panel a plurality of attachment elements, each including a slider movable between an installed position where the ceiling panel is connected to co-operating support members of a support structure and an uninstalled position where the ceiling panel is disconnected from the at least one support member, the slider comprising a magnetic element; and connecting the ceiling panel to the co-operating support members of the support structure by moving the slider of each attachment element from an uninstalled position to an installed position in which the slider co-operates with a co-operating support member to connect the ceiling panel to the support structure, wherein each slider is movable in either direction between the uninstalled position and the installed position by co-operation of the magnetic element of each slider with a magnetic element of a tool separated from the slider by the ceiling panel.

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