Felt Slat Ceiling Tiles for Tool-Free Acoustic Installation
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Solution Overview
Problem
Existing drop ceiling systems require tools and additional hardware for installation, and there is a need for a dynamic acoustic system that provides an aesthetically pleasing undulating image while reducing unwanted noise.
Innovation Solution
A drop ceiling product made from recycled polyester felt with installation slots, allowing for easy installation into a backer panel and drop ceiling hangers without tools, creating an undulating image and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional drop ceiling systems use additional supports, attachment hardware and clips, then the structure can be suspended to the drop ceiling, but tools are required to assemble and suspend the structure
Solution Approach 1:
The patent combines the ceiling component, attachment hardware, and support structure into a single integrated unit. The ceiling component includes integrated tabs that directly engage with the drop ceiling hanger system, eliminating the need for separate clips, supports, or attachment hardware. This merging of functions allows the ceiling component to be suspended directly without requiring additional components or tools for assembly.
Solution Approach 2:
The ceiling component is designed with self-installing tabs that automatically engage with the drop ceiling hanger system when the component is placed into position. The tabs are configured to snap or clip into the hanger grid without requiring manual assembly tools or additional hardware, allowing the component to install itself through its own integrated attachment mechanism.
2Device complexity
If traditional drop ceiling systems require tools and additional hardware, then the installation process becomes complex, but the structural support is adequate
Solution Approach 1:
The patent combines the ceiling component, attachment hardware, and support structure into a single integrated unit. The ceiling component includes integrated tabs that directly engage with the drop ceiling hanger system, eliminating the need for separate clips, supports, or attachment hardware. This merging of functions allows the ceiling component to be suspended directly without requiring additional components or tools for assembly.
Solution Approach 2:
The attachment tabs are pre-configured and pre-integrated into the ceiling component during manufacturing. The tabs are positioned and shaped in advance to match the drop ceiling hanger system, so that when the component is installed, the attachment mechanism is already prepared and requires no on-site assembly or adjustment, significantly reducing installation time.
3Shape
If straight ceiling products are used, then installation is simple, but the aesthetic appeal and acoustic performance are limited
Solution Approach 1:
The patent employs ceiling components with curved, undulating, or wave-like profiles instead of straight lines. These curved shapes create dynamic visual effects and improve acoustic performance by scattering sound waves. The curvature is achieved through forming processes that shape the ceiling material into波浪 patterns while maintaining the integrated attachment tabs for straightforward installation.
Solution Approach 2:
The patent varies parameters such as the curvature radius, wave amplitude, and profile geometry of the ceiling components to achieve different aesthetic effects and acoustic performance levels. By changing these parameters, the same basic component design can produce multiple visual styles and acoustic characteristics without requiring completely different manufacturing processes.
Data Source
AI summary
A ceiling system comprising a plurality of ceiling tiles each comprising a plurality of felt slats. The plurality of felt slats are arranged parallel to one another and include first and second recesses configured to receive and engage a ceiling hanger system.