Ceiling Panel Attachment System with Spring Yokes
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Solution Overview
Problem
Existing systems for attaching ceiling panels to T-bar grids face challenges in maintaining straight and uniform lines due to installation and manufacturing tolerances, which also hinder reliable access to the space above the panels for maintenance.
Innovation Solution
A system comprising plates with standoffs attached to the ceiling panels, spring yokes that move in a plane parallel to the panel's upper surface, and springs that couple the spring yokes to the grid of suspended bars, along with alignment clips and stiffener bars, to ensure proper alignment and access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard clips are used to hang ceiling panels from T-bar grids, then installation is simple, but manufacturing and installation tolerances cause non-uniform spacing and misalignment between panels
Solution Approach 1:
The patent introduces an intermediary alignment system consisting of alignment clips and adjustment mechanisms that mediate between the standard T-bar grid and the ceiling panels. These intermediaries compensate for tolerances in both the grid and panels, enabling uniform spacing and straight reveal lines without requiring high precision in the original components.
Solution Approach 2:
The patent employs adjustable parameters in the alignment system, allowing installers to modify the position and orientation of panels relative to the grid. This adjustability compensates for tolerance variations and enables achievement of uniform spacing and alignment despite imperfections in manufacturing tolerances of the T-bar grid and panels.
2Stability of the object's composition
If panels are tightly attached to the grid for stability, then ceiling structure is secure, but access to the space above panels for maintenance is hindered
Solution Approach 1:
The patent implements a dynamic attachment system where panels can be easily installed and secured during normal operation, but can also be quickly released and removed when maintenance is required. The alignment clips and suspension mechanism allow the ceiling to transition between a stable installed state and an accessible maintenance state, accommodating both structural security and operational flexibility.
3Manufacturing precision
If tolerance compensation mechanisms are added to achieve uniform panel spacing, then alignment improves, but device complexity increases
Solution Approach 1:
The patent extracts the alignment and tolerance compensation function into separate, modular components (alignment clips, adjustment mechanisms) that can be independently manufactured and installed. This separation allows the core suspension system to remain simple while adding complexity only where needed for alignment, rather than making the entire attachment system complex.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for the installation of ceiling panels with clean reveal lines and provides ready access to the space above the panels for maintenance, compensating for variations in installation and manufacturing tolerances.
Implementation Method 1
a plurality of springs, each spring configured for coupling a corresponding one of the spring yokes to the grid of suspended bars
Implementation Method 2
an alignment clip attached to the upper surface of the ceiling panel, the alignment clip including a flat surface configured to rest against one of the suspended bars to align the ceiling panel with the grid through movement of the spring yokes in the plane parallel to the upper surface of the ceiling panel
Data Source
AI summary
An attachment system providing for connecting ceiling panels to a grid of suspended T-bars, may include plural plates attached to the upper surface of the ceiling panel. Each plate may include a standoff that offsets the plate's main surface to provide a space between the plate and the panel where a yoke may be captured but remain movable in a horizontal plane a sufficient amount to improve alignment of the ceiling panels. Each spring yoke may couple a spring to a slot on a spring holster on the grid of suspended bars. Each spring may be provided with first and second positioning mechanisms cooperating with the slot in the spring holster to provide an installed position and an accessible position. The system may include one or more alignment clips and stiffener clips and stiffener bars. The alignment clips may cooperate with the spring yokes' movability relative to the panel for alignment of adjacent panels. The stiffener bars may cooperate with the stiffener clips and the plates to allow horizontal expansion and contraction and prevent vertical warping of the panel.