Background

Field of the Invention.

Ceilings of the suspended type use beams extending in grid form to support tile.

The beams are of an inverted T cross section having either a flat or a channel bottom flange.

This invention relates to the bottom flange.

Prior Art Sometimes, it is desirable to use the beams and tiles in a suspended ceiling to achieve a decorative effect. An example is the achievement of a three-dimensional effect, as for instance by the use of a channel flange and a beveled tile. Such a prior art construction is shown, for instance, in U.S. Patent No. 4,422,272 (the \'272 patent) . The inside of the channel may be of a different color from the outside. A beveled edge tile is often used with such an arrangement where the tile may be of the color that is inside the channel or still a third color on the tile may be used. Such prior art ceiling yields a three-dimensional effect and, when different colors are used, an additional color effect.

Such a ceiling, although pleasing to view, is more expensive than a "flat" ceiling wherein a flat tile rests on a flat flange, because of the channel design.

Where continuity of the flange is desired at the beam intersections, one solution has been to place a notch on the support member at the intersection, but this substan¬ tially weakens the U-channel flange. Another solution is use a clip of the groove color disclosed in the \'272 patent.

Such clip adds to the cost and complexity of the ceiling.

Summary of the Present Invention

The _. present invention achieves a three-dimensional effect, and optionally, a color, material, or texture effect, in what is a flat ceiling. By a flat ceiling is meant one in which the flanges of the T cross section grid beams are relatively thin and flat, as commonly produced for suspended ceilings, and the tile supported by the flanges is flat. Such a ceiling is the most economical to produce and install. The three-dimensional effect is achieved by pro¬ ducing a flange which is formed by wrapping outer bends from a first strip from which the beam is being formed around a flat second strip, so that the effect from below is that of two surface levels in the flange, projecting to one standing on the floor and gazing at the ceiling, a pronounced three- dimensional effect. The second strip may be of a different material, texture, or color from the first material, to provide a decorative color effect and, in some instance, an even more pronounced three-dimensional effect. Optionally, the bends of the flange may be cut out or notched at the intersections, exposing the inner second strip at these intersections in either direction. There is but a small amount of loss of beam strength from the notch at these intersections since the upper layer of the flange formed by the bends as well as the inner second strip remain intact at the cutouts. In effect what is a two-ply flange with lower bends is reduced in the vicinity of the inter¬ section to two-ply only, which is more than adequate to maintain the integrity of the flange. In effect, the present invention uses a flat flange

T beam to achieve the three-dimensional effect of a channel

T flange beam, without the increased cost and complexity of such prior art ceiling. Other effects can be obtained, when desired, by making the second strip of a different color, material, or texture from the first strip.

Brief Description of the Drawings

FIGURE 1 is a fragmentary perspective view illus¬ trating a portion of a typical metallic beam member having a channel flange for the support of ceiling tiles or panels. Two fragmentary tiles are shown in the drawing; the left-hand panel being slightly elevated above the channel supporting flange to show the stepped configuration of the tile edge. The metallic beam member is often of a single color of white, but sometimes has a different color in the inner groove. This type of ceiling grid and panel construction is well known and is designated prior art.

FIGURE 2 is an enlarged fragmentary sectional elevational view taken on the line 2,2 of FIG. 1, clearly showing details of the channel flange supporting the stepped edge of the ceiling tiles and designated prior art.

FIGURE 3 is a fragmentary bottom plan view taken on the line 3,3 of FIG. 2, illustrating additional visual details.

FIGURE 4 is a fragmentary perspective view illus¬ trating a portion of metallic grid member in the form of an inverted T with flanges that support ceiling tiles. Two fragmentary portions of ceiling tiles are shown in position in the drawing. The flange includes a second strip that is secured within the rolled flats of the flange, \'exposing the strip in a centrally located axially extending plane between the rolled-over flats of the flange.

FIGURE 5 is an enlarged fragmentary sectional eleva- tional view taken on the line 5,5 of FIG. 4, showing details of the tile supporting flange and the included strip, secured by the rolled flats of the flange. The flange is shown supporting two fragmentary end portions of conventional ceil¬ ing tile.

FIGURE 6 is a fragmentary plan view taken on the line 6,6 of FIG. 5, showing the visual effect created when the flange flats are of a different color from the tiles and the centrally located second strip is of a -contrasting color.

FIGURE 7 is a fragmentary perspective view showing a portion of metallic beam member having a lower terminal flange of the inverted T configuration and the second strip of this invention being intersected and interlocked by the terminal ends of two additional metallic beam members of like design. The beam members are shown supporting fragmentary end portions of three tiles or panels and the inner strips are continuous through the point of intersection.

FIGURE 8 is an enlarged fragmentary sectional eleva- tional view taken on the line 8,8 of FIG. 7, showing details of the interlocking beam members at a point of intersection, the abutment of the flanges of the left and right beam mem¬ bers to the centrally located beam flange and details of the cutout provided in the flange of the centrally located beam providing an aligned pathway for the strip.

FIGURE 9 is a plan view taken on the line 9,9 of FIG. 8, illustrating the uninterrupted intersection of strip provided by the cutout.

Brief Description of the Preferred Embodiment

Prior Art

As seen in FIGS. 1 through 3, a beam (20) suspended in the usual way, has a bulb (21) , web (22) and channel (23) with inwardly extending flats (25) folded back at (26) . A tile (27) has an edge groove (28) so that the bottom (30) of tile (27) lies in a horizontal plane close to that of the plane of flats (25) . As set forth in the \'272 patent referred to earlier, the groove (31) in channel (23) is of a different color than flats (25) . Tile (27) can be of the same color as either groove (31) or flats (25) , or of a still different color. The total effect to a viewer from below is a three- dimensional color contrast.

Where continuity of the groove color is desired in all directions, at the intersection of the support beams with the transverse beams, it is necessary to either notch the channel or provide a special clip in order to provide continuity of the groove color in all directions, as seen in the \'272 patent.

The Present Invention

The present invention as seen in FIGS. 4 through 6 corresponds to FIGS. 1 through 3 described above as prior art. Beam (35) has, in conventional fashion, a bulb (36) , a web (37), and a relatively flat flange (38) . It is flange (38) which is different and provides the invention.

When beam (35) is formed by, for instance, rolls, a first strip of metal (39) of a first color is bent sym¬ metrically about the longitudinal center line, as well known, to form the bulb (36) , and then bent into adjacent layers to form web (37) . Each edge of the first strip (39) is then

flared outwardly opposite one another to begin forming the flange of- he T at (40) . At this point, a flat second- strip (41) , preferably, but not necessarily, of a different ^\' material, texture, or color from strip (39) , of a suitable width so as to permit first strip (39) to be bent around inner flat strip (41) at (42) and (43), is laid against the oppos¬ itely flared upper layer of flange (38) . Strip (41) may be of metal, either similar or dissimilar to the flange metal; a vinyl, a fabric, or other suitable material,which may or may not have structural strength of its own.

Strips (39) and (41) are then continuously bent by the rolls until they achieve the final construction of flange (38) as seen for instance in cross section in FIG. 5. In such form, longitudinally extending flats (43) and (45) are. formed along the exposed portion of longitudinally ex¬ tending inner second strip (41) . Flats (43) and (45) extend in a horizontal plane below the horizontal surface of second strip (41) .

When viewed from below, as seen in FIGS. 4 and 6, flats (43) and (45) extend on either side of the exposed portion of strip (39) and are preferably of a different color and/or texture. The color and/or texture is applied to strips (39) and (41) when they are in flat, continuous web form, and before the strips are fabricated into the grid beam (35) described.

Flat tiles, or panels (46) are laid on flange (38) in the conventional manner. Tiles (46) may be of the same color as either flats (43) and (45) or strip 39, or of a different color. When viewed from below, the ceiling of the inven¬ tion achieves a three-dimensional effect among the tiles (46),

flats (43) and (45) , and strip (41) . Particularly where a dark color, such as a dark bronze, is used on the inner strip (41) , and an off-white on the flats, the effect is remarkably similar to that of the prior art channel flange described earlier. The slightly different plane of the inner strips and flats also contribute to the marked three- dimensional effect.

Additionally, in the prior art channel flange, it is necessary to use a grooved tile to bring its lower surface down toward the flats (25) of the channel (23) , to avoid an unattractive vertical expanse between the flats (25) and the lower surface of the tile (27) , as seen in FIGS. 1 through 3. An edge groove adds to the expense of the tile. No such grooved tile is necessary in the present invention. A regu- lar, prior art, flat tile (46) is used. The lower surface of the tile is above the surface of flats (43) and (45) , thus contributing to the three-dimensional effect.

It may be desirable to have continuous uninterrupted second strip (41) exposure in all directions at beam inter- sections. In FIGS. 7 through 9, there is shown the construc¬ tion of flange (38) at the intersection of a main beam (50) and an intersecting beam (51) , when the flange is notched. Beam (51) has a tongue (52) , of any prior art design, passing through a slot (53) in main beam (50) and hooking thereto, again as well known.

Flats (43) and (45) are cut away at (55) to an extent that conforms to the width of the inner second strip (41) on intersecting beams (50) and (51) , as seen in FIGS. 7 and 9. Such cutout yields a cross shape of inner strip (41)

and is desirably formed during the fabrication of the grid beam (35) by cutting the flat strips (39) and (41) prior to the bending operation as described earlier. The location of the cutout can be coordinated with the punching of slot (53) .

Flange (38) is cut to provide an offset at (47) as is well known in the construction of intersecting beams for grid ceilings.

Main grid beam (50) remains relatively strong at the cutout location at (56) , since flange (38) still has its upper surface as well as any structural strength from the inner flat strip (41) . Of course, the beam continues to have the structure of web (37) and bulb (36) .

When the beam construction of the invention is notched, when viewed from below as in FIGS. 7 and 9, the intersecting grid beams have continuous cross-shaped con¬ trasting color exposed inner strip (41) , with flat tiles (46) supported from flanges (38) .