Patterned Ceiling Grid Runners for Aesthetic Blending
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Solution Overview
Problem
Existing ceiling suspension systems in buildings have a featureless, smooth exposed grid that contrasts with ceiling tiles, making it difficult to diminish visibility or match the aesthetic appeal, with previous attempts at modification being aesthetically unappealing and unsuccessful.
Innovation Solution
The system incorporates patterned surfaces on support members, such as main runners, cross tees, and wall angles, with textured features like lines, slots, dimples, protrusions, and cross-hatching, which are roll-formed, stamped, or mechanically impressed to create a non-smooth, visually appealing appearance that blends with ceiling tiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the exposed grid surfaces are kept smooth and flat for ease of manufacture, then manufacturing simplicity is maintained, but the aesthetic appeal and visual blending with ceiling tiles deteriorates
Solution Approach 1:
The patent applies local quality by introducing patterns only on the exposed cap surfaces of the grid members while maintaining smooth surfaces on non-exposed portions. This allows the aesthetic enhancement to be localized where it is visually apparent, without complicating the entire manufacturing process. The patterned caps are integrated into the existing roll-forming process, so only specific local areas require additional processing steps.
Solution Approach 2:
The patent transitions from two-dimensional flat surfaces to three-dimensional textured surfaces by adding raised or recessed patterns to the cap surfaces. This dimensional change creates visual interest and helps the grid blend with ceiling tiles by matching their textured appearance, while the patterns are formed through additional forming operations that build upon the basic roll-formed structure.
2Shape
If patterned surfaces are added to support members to improve aesthetic appeal, then visual blending with ceiling tiles is enhanced, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies preliminary action by incorporating pattern formation into the roll-forming process itself, rather than adding patterns after the grid members are manufactured. The patterns are created during the initial forming operation through specially designed forming rolls, which pre-pattern the cap surfaces as the metal is being shaped. This eliminates the need for separate post-processing steps and reduces overall manufacturing complexity.
Solution Approach 2:
The patent changes the surface parameters of the cap surfaces by introducing varied textures, heights, and patterns through the roll-forming process. By adjusting the forming roll configurations, different pattern parameters (such as pattern depth, spacing, and geometry) can be achieved, allowing aesthetic customization without fundamentally changing the manufacturing system or requiring complex additional equipment.
Data Source
AI summary
A ceiling suspension system has support members that are interconnected to support ceiling panels. The ceiling suspension system is suspended from a building. Each of the support members has a lower surface that is patterned and different in textural appearance than other portions of the support members to define patterned lower surfaces. For example, the patterned lower surfaces may have non-smooth textures that are uniform and symmetrical, or non-uniform and irregular. The patterned lower surfaces may have three-dimensional features such as lines, slots, dimples, protrusions, peaks and valleys and/or cross-hatching, which may be roll-formed on capping on the support members.