Suspended Ceiling Saddle Bracket Alignment
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Solution Overview
Problem
Existing suspended ceiling systems face challenges in maintaining alignment of edges, controlling panel level, and achieving an adequate air seal between the support grid and ceiling panels, leading to visible height variations and air leakage issues.
Innovation Solution
A ceiling system comprising a grid support with struts and connection assemblies, including mounting brackets with resilient elements and saddle brackets, which provide vertical and horizontal registration and locking mechanisms to ensure precise panel alignment and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If simple inexpensive suspended ceiling systems are used, then cost is reduced, but alignment of edges and control of panel level deteriorate
Solution Approach 1:
The patent employs resilient elements (springs) in the connection assemblies that provide dynamic adjustment capability. These springs allow the mounting brackets to move vertically and horizontally within defined ranges, enabling automatic alignment of panel edges and leveling during installation while maintaining a simple overall structure.
Solution Approach 2:
The connection assemblies incorporate adjustable parameters through resilient elements that can change the position and orientation of mounting brackets. The springs allow variation in vertical and horizontal positions, enabling precise alignment of panel edges and control of panel level without complicating the basic system design.
2Device complexity
If simple suspended ceiling systems are used, then device complexity is reduced, but air seal between support grid and ceiling panels deteriorates
Solution Approach 1:
The resilient elements act as intermediaries between the mounting brackets and the support grid. These springs maintain continuous contact and apply consistent pressure, ensuring reliable sealing between the ceiling panels and the grid structure while adding minimal complexity to the overall system.
Solution Approach 2:
The dynamic nature of the resilient elements allows the connection assemblies to adapt to minor variations in installation, maintaining effective air sealing through continuous contact pressure without requiring complex adjustment mechanisms or additional sealing components.
3Manufacturing precision
If resilient elements are added to connection assemblies, then alignment and sealing improve, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the resilient elements themselves. The springs simultaneously provide vertical adjustment, horizontal alignment, sealing pressure, and structural connection. This integration achieves precise alignment and reliable sealing without adding separate components, thereby limiting the increase in device complexity.
Solution Approach 2:
The resilient elements serve multiple purposes within the connection assembly: they act as structural connectors, alignment guides, sealing elements, and adjustment mechanisms. This multi-functionality allows the system to achieve precise alignment and effective sealing while adding minimal complexity, as a single component performs multiple critical roles.
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 ensures straight edge alignment, controlled panel level, and improved air sealing, enhancing the appearance and functionality of suspended ceiling systems.
Implementation Method 1
The resilient element is detachably coupled to the saddle bracket. The resilient element biases the mounting bracket, the flange portion of the strut, and the support flange of the saddle bracket together.
Data Source
AI summary
A grid assembly for hanging a ceiling panel, and a ceiling system including the same, and a saddle bracket for use with the same. The grid assembly may comprise a grid support comprising a strut comprising a flange portion, a web portion, a bulb portion. The bulb portion may comprise an undersurface. The saddle bracket may comprise a horizontal locking feature, a vertical locking feature, a panel mounting feature, and a web receiving cavity. The saddle bracket may be mounted to the strut so that the vertical locking feature engages the undersurface of the bulb portion to vertically lock the saddle bracket to the strut and the horizontal locking feature of the saddle bracket may be alterable between locked and unlocked states.