CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a PCT International Application claiming priority to United States Provisional Patent Application No. 63/434,201, filed on December 21, 2022, and United States Provisional Patent Application No. 63/342,254, filed on May 16, 2022, the disclosures of which are incorporated herein by reference in their entireties.

FIELD

[0002] The present invention relates to suspended surface covering systems, and more particularly to surface covering systems comprising a plurality of slats arranged substantially parallel with one another.

BACKGROUND

[0003] Numerous types of suspended surface covering systems and methods for mounting ceiling panels and slats have been used. Each of these surface covering systems and methods for mounting ceiling panels and slats has a different aesthetic value, installation requirements, and functional benefits such as acoustic reduction and thermal insulation value. Slat type surface covering systems offer advantages in unique appearance, ease of installation, and ventilation flexibility.

[0004] Slat type surface covering systems frequently have difficulty with warping and bowing of the slats. This causes an undesirable uneven appearance.

[0005] Improvements in slat type surface covering systems are desired to ensure that the slat warping and bowing is minimized.

SUMMARY

[0006] In one aspect, the invention may be a surface covering system incorporating a grille assembly configured to be mounted to a support structure. The grille assembly has a plurality of slats, a plurality of cross-backer beams, and a plurality of primary angled backer beams. Each of the plurality of slats are substantially parallel to one another and extend along a slat axis from a first end to a second end. Each of the slats have vertically oriented first and second major surfaces, a bottom edge extending between the first and second major surfaces, and a top edge extending between the first and second major surfaces. Each of the cross-backer beams extending along a cross-beam axis and oriented so that the cross-beam axis extends substantially perpendicular to the slat axes of the slats. Each of the cross-backer beams is coupled to each of the slats. The cross-backer beams are spaced apart from one another along the slat axes of the slats to form a plurality of bays between adjacent ones of the cross-backer beams. Each of the primary angled backer beams extend along a primary angled beam axis from a proximal end to a distal end and are positioned within one of the bays and oriented so that the primary angled beam axis extends obliquely to the slat axes of the slats. Each of the primary angled backer beams is coupled to the slats.

[0007] In another aspect, the invention may be a surface covering system incorporating a grille assembly configured to be mounted to a support structure. The grille assembly has at least three slats and a plurality of angled backer beams. The at least three slats are arranged substantially parallel to one another, each of the at least three slats extending along a slat axis from a first end to a second end and comprising vertically oriented first and second major surfaces, a bottom edge extending between the first and second major surfaces, and a top edge extending between the first and second major surfaces. Each of the angled backer beams extend along an angled beam axis, are oriented so that the angled beam axis extends obliquely to the slat axes of the at least three slats, and are coupled to the at least three slats.

[0008] In yet another aspect, the invention may be a surface covering system incorporating a grille assembly configured to be mounted to a support structure. The grille assembly has a plurality of first cross-backer beams, a plurality of second cross-backer beams, and a plurality of slats. Each of the plurality of first cross-backer beams extend along a first cross-beam axis and have a first top surface, a first bottom surface, and a plurality of first notches formed in the first bottom surface. Each of the first notches have a first depth measured from the first bottom surface to a first floor surface of the first notch. Each of the second cross-backer beams extend along a second cross-beam axis and have a second top surface, a second bottom surface, and a plurality of second notches formed in the second bottom surface. Each of the second notches have a second depth measured from the second bottom surface to a second floor surface of the second notch, the second depth being greater than the first depth. The first and second crossbacker beams are arranged in a spaced apart manner, the first and second cross-backer beams oriented so that the first and second cross-beam axes are substantially parallel with one another. Each of the plurality of slats extends along a slat axis from a first end to a second end and have vertically oriented first and second major surfaces, a bottom edge extending between the first and second major surfaces, and a top edge extending between the first and second major surfaces. The slats are mounted to the first and second cross-backer beams so that top portions of the slats nest in the first and second notches so that the top edges of slats contact the first and second floor surfaces, the slats arranged substantially parallel to one another.

[0009] In another aspect, the invention may be a surface covering system incorporating a grille assembly configured to be mounted to a support structure. The grille assembly has a plurality of first cross-backer beams, a plurality of second cross-backer beams, and a plurality of slats. Each of the plurality of first cross-backer beams extend along a first cross-beam axis and have a first top surface, a first bottom surface, and a first height measured from the first bottom surface to the first top surface. Each of the second cross-backer beams extend along a second cross-beam axis and have a second top surface, a second bottom surface, and a second height measured from the second bottom surface to the second top surface. The second height is greater than the first height. The first and second cross-backer beams are arranged in a spaced apart manner, the first and second cross-backer beams oriented so that the first and second cross-beam axes are substantially parallel with one another. Each of the plurality of slats are mounted to the first and second cross-backer beams, each of the slats extending along a slat axis from a first end to a second end and have vertically oriented first and second major surfaces. Each of the slats has a bottom edge extending between the first and second major surfaces and a top edge extending between the first and second major surfaces.

[0010] In another aspect, the invention may be a surface covering system incorporating a grille assembly configured to be mounted to a support structure. The grille assembly has a plurality of cross-backer beams and a plurality of slats. Each of the plurality of cross-backer beams extend along a cross-beam axis and have a top surface, a bottom surface, and a plurality of notches formed in the first bottom surface. Each of the notches have a depth measured from the bottom surface to a floor surface of the notch. The cross-backer beams are arranged in a spaced apart manner and are oriented so that the cross-beam axes are substantially parallel with one another. Each of the plurality of slats extend from a first end to a second end and have vertically oriented first and second major surfaces. Each of the slats has a bottom edge extending between the first and second major surfaces and a top edge extending between the first and second major surfaces. Each of the slats has a height measured from the bottom edge to the top edge. A ratio of the depth to the height is equal to or greater than 0.31:1. The slats are mounted to the cross-backer beams so that top portions of the slats next in the notches so that the top edges of the slats contact the floor surfaces, the slats arranged substantially parallel to one another. [0011] In yet another aspect, the invention may be a surface covering system incorporating a grille assembly configured to be mounted to a support structure. The grille assembly has a plurality of cross-backer beams and a plurality of slats. Each of the plurality of cross-backer beams extend along a cross-beam axis and have a top surface, a bottom surface, and a plurality of notches formed in the first bottom surface. Each of the notches have a depth measured from the bottom surface to a floor surface of the notch. The cross-backer beams are arranged in a spaced apart manner and are oriented so that the cross-beam axes are substantially parallel with one another. Each of the plurality of slats extend from a first end to a second end and have vertically oriented first and second major surfaces. Each of the slats has a bottom edge extending between the first and second major surfaces and a top edge extending between the first and second major surfaces. Each of the slats has a height measured from the bottom edge to the top edge. A ratio of the depth to the height is equal to or greater than 0.35:1. The slats are mounted to the cross-backer beams so that top portions of the slats next in the notches so that the top edges of the slats contact the floor surfaces, the slats arranged substantially parallel to one another.

[0012] In another aspect, the invention may be a surface covering system incorporating a grille assembly configured to be mounted to a support structure. The grille assembly has a plurality of cross-backer beams and a plurality of slats. Each of the plurality of cross-backer beams extend along a cross-beam axis and have a top surface, a bottom surface, and a plurality of notches formed in the first bottom surface. Each of the notches have a pair of opposing sidewall surfaces extending from the bottom surface to a floor surface. At least one of the plurality of notches has a radiused comer between the floor surface and at least one of the opposing sidewall surfaces. The cross-backer beams are arranged in a spaced apart manner and are oriented so that the cross-beam axes are substantially parallel with one another. Each of the plurality of slats extend from a first end to a second end and have vertically oriented first and second major surfaces. Each of the slats has a bottom edge extending between the first and second major surfaces and a top edge extending between the first and second major surfaces. The slats are mounted to the cross-backer beams so that top portions of the slats next in the notches so that the top edges of the slats contact the floor surfaces, the slats arranged substantially parallel to one another.

[0013] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The features of the exemplary embodiments of the present invention will be described with reference to the following drawings, where like elements are labeled similarly, and in which:

[0015] FIG. 1 is an elevation view of an exemplary building with a surface covering system according to the present invention.

[0016] FIG. 2 is a perspective view of the surface covering system as illustrated in FIG. 1.

[0017] FIG. 3 is a an exploded perspective view of the surface covering system of FIG. 2.

[0018] FIG. 4 is a detail view of a portion of the surface covering system of FIG. 2.

[0019] FIG. 5 is a perspective view of an exemplary bracket as may be used to assemble the surface covering system of FIG. 2.

[0020] FIG. 6 is a perspective view illustrating installation of the bracket of FIG. 5.

[0021] FIG. 7 is a schematic view of the surface covering system installed to furring strips.

[0022] FIG. 8 is a perspective view of another installation means for the surface covering system.

[0023] FIG. 9 is a perspective view of a grille assembly, a plurality of which form the surface covering system of FIG. 2.

[0024] FIG. 10 is a top view of the grille assembly of FIG. 9.

[0025] FIG. 11 is a front view of the grille assembly of FIG. 9.

[0026] FIG. 12 is a right side view of the grille assembly of FIG. 9.

[0027] FIG. 13 is an exploded perspective view of the grille assembly of FIG. 9.

[0028] FIG. 14 is a perspective view of a first cross-backer beam as used in the grille assembly of FIG. 9.

[0029] FIG. 15 is a top view of the first cross-backer beam of FIG. 14.

[0030] FIG. 16 is a right side view of the first cross-backer beam of FIG. 14.

[0031] FIG. 17 is a perspective view of an angled backer beam as used in the grille assembly of FIG. 9.

[0032] FIG. 18 is a top view of the angled backer beam of FIG. 17.

[0033] FIG. 19 is a right side view of the angled backer beam of FIG. 17. [0034] FIG. 20 is a perspective view of a second cross-backer beam as used in the grille assembly of FIG. 9.

[0035] FIG. 21 is a top view of the second cross-backer beam of FIG. 1620

[0036] FIG. 22 is a right side view of the second cross-backer beam of FIG. 20.

[0037] FIG. 23 is a perspective view of a second embodiment of a grille assembly as may be used in the surface covering system of FIG. 2.

[0038] FIG. 24 is a top view of the grille assembly of FIG. 23.

[0039] FIG. 25 is a front view of the grille assembly of FIG. 23.

[0040] FIG. 26 is a right side view of the grille assembly of FIG. 23.

[0041] FIG. 27 is a perspective view of a third embodiment of a grille assembly as may be used in the surface covering system of FIG. 2.

[0042] FIG. 28 is a top view of the grille assembly of FIG. 27.

[0043] FIG. 29 is a front view of the grille assembly of FIG. 27.

[0044] FIG. 30 is a right side view of the grille assembly of FIG. 27.

[0045] FIG. 31 is an exploded perspective view of the grille assembly of FIG. 27.

[0046] FIG. 32 is a perspective view of an angled backer beam as used in the grille assembly of FIG. 27.

[0047] FIG. 33 is a top view of the angled backer beam of FIG. 32.

[0048] FIG. 34 is a right side view of the angled backer beam of FIG. 32.

[0049] FIG. 35 is a perspective view of a fourth embodiment of a grille assembly as may be used in the surface covering system of FIG. 2.

[0050] FIG. 36 is a top view of the grille assembly of FIG. 35.

[0051] FIG. 37 is a front view of the grille assembly of FIG. 35.

[0052] FIG. 38 is a right side view of the grille assembly of FIG. 35.

[0053] FIG. 39 is a perspective view of a fifth embodiment of a grille assembly as may be used in the surface covering system of FIG. 2.

[0054] FIG. 40 is a top view of the grille assembly of FIG. 39.

[0055] FIG. 41 is a front view of the grille assembly of FIG. 39.

[0056] FIG. 42 is a right side view of the grille assembly of FIG. 39.

[0057] FIG. 43 is a perspective view of a primary angled backer beam as used in the grille assembly of FIG. 39.

[0058] FIG. 44 is a top view of the primary angled backer beam of FIG. 43.

[0059] FIG. 45 is a right side view of the primary angled backer beam of FIG. 43. [0060] FIG. 46 is a perspective view of a secondary angled backer beam as used in the grille assembly of FIG. 39.

[0061] FIG. 47 is a top view of the secondary angled backer beam of FIG. 46.

[0062] FIG. 48 is a right side view of the secondary angled backer beam of FIG. 46.

[0063] FIG. 49 is a perspective view of a sixth embodiment of a grille assembly as may be used in the surface covering system of FIG. 2.

[0064] FIG. 50 is a top view of the grille assembly of FIG. 49.

[0065] FIG. 51 is a front view of the grille assembly of FIG. 49.

[0066] FIG. 52 is a right side view of the grille assembly of FIG. 49.

[0067] FIG. 53 is a perspective view of a seventh embodiment of a grille assembly as may be used in the surface covering system of FIG. 2.

[0068] FIG. 54 is a top view of the grille assembly of FIG. 53.

[0069] FIG. 55 is a front view of the grille assembly of FIG. 53.

[0070] FIG. 56 is a right side view of the grille assembly of FIG. 53.

[0071] FIG. 57 is a perspective view of a first cross-backer beam as used in the grille assembly of FIG. 53.

[0072] FIG. 58 is a top view of the first cross-backer beam of FIG. 57.

[0073] FIG. 59 is a right side view of the first cross-backer beam of FIG. 57.

[0074] FIG. 60 is a perspective view of a second cross-backer beam as used in the grille assembly of FIG. 53.

[0075] FIG. 61 is a top view of the second cross-backer beam of FIG. 60.

[0076] FIG. 62 is a right side view of the second cross-backer beam of FIG. 60.

[0077] FIG. 63 is a perspective view of an alternate second cross-backer beam as may be used in the grille assembly of FIG. 53.

[0078] FIG. 64 is a top view of the second cross-backer beam of FIG. 63.

[0079] FIG. 65 is a right side view of the second cross-backer beam of FIG. 63.

[0080] FIG. 66 is a perspective view of another alternate second cross-backer beam as may be used in the grille assembly of FIG. 53.

[0081] FIG. 67 is a top view of the second cross-backer beam of FIG. 66.

[0082] FIG. 68 is a right side view of the second cross-backer beam of FIG. 66.

[0083] FIG. 69 is a detail view of a notch of the second cross-backer beam of FIG. 68.

[0084] FIG. 70 is a perspective view of an eighth embodiment of a grille assembly as may be used in the surface covering system of FIG. 2.

[0085] FIG. 71 is a top view of the grille assembly of FIG. 70. [0086] FIG. 72 is a front view of the grille assembly of FIG. 70.

[0087] FIG. 73 is a right side view of the grille assembly of FIG. 70.

[0088] FIG. 74 is a perspective view of a first cross-backer beam as used in the grille assembly of FIG. 70.

[0089] FIG. 75 is a top view of the first cross-backer beam of FIG. 74.

[0090] FIG. 76 is a right side view of the first cross-backer beam of FIG. 74.

[0091] FIG. 77 is a perspective view of a ninth embodiment of a grille assembly as may be used in the surface covering system of FIG. 2.

[0092] FIG. 78 is a top view of the grille assembly of FIG. 77.

[0093] FIG. 79 is a front view of the grille assembly of FIG. 77.

[0094] FIG. 80 is a right side view of the grille assembly of FIG. 77.

[0095] FIG. 81 is a graph of the spacing between badly twisted slats for cross-backer beams having two different notch depths.

[0096] FIG. 82 is a graph of the spacing between terribly twisted slats for cross-backer beams having two different notch depths.

[0097] FIG. 83 is a graph of the spacing for various combinations of cross-backer beams having different notch depths.

[0098] FIG. 84 is a graph of the effect of notch comer radius on shear strength of the crossbacker beams.

[0099] All drawings are schematic and not necessarily to scale. Parts given a reference numerical designation in one figure may be considered to be the same parts where they appear in other figures without a numerical designation for brevity unless specifically labeled with a different part number and described herein.

DETAILED DESCRIPTION

[00100] The features and benefits of the invention are illustrated and described herein by reference to exemplary (“example”) embodiments. This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. Accordingly, the disclosure expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features.

[00101] In the description of embodiments disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as "lower," "upper," “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

[00102] As used throughout, any ranges disclosed herein are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range.

[00103] Fig. 1 illustrates an exemplary building implementing a surface covering system 10 installed in a building 11. As can be seen, the surface covering system 10 is supported by a building support structure 12. The building support structure 12 may be a part of a ceiling or roof structure and may be coupled to the load bearing walls of the building 11, either directly or indirectly. As will be discussed in greater detail, a grid assembly 14 is coupled to the building support structure 12. The grid assembly 14 forms a part of the surface covering system 10 and is coupled to the building support structure 12. The grid assembly 14 may be suspended via a plurality of hangers 16. The plurality of hangers 16 may be cables, chains, wires, ropes, or simply mounted directly to the building support structure 12. The grid assembly 14 receives a plurality of grille assemblies 100 which form the portion of the surface covering system 10 which is visible to a user.

[00104] Turning to Figs. 2-4, the surface covering system 10 is shown in greater detail. The surface covering system 10 comprises the grid assembly 14 and the plurality of grille assemblies 100. The grid assembly 14 may be formed of any material suitable to support the weight of the grille assemblies 100. For instance, the grid assembly 14 may be a grid of members having a structural profile such as a T, I, or similar profile. In other implementations, the grid assembly 14 may be attached to a wall of the building 11 instead of a ceiling. For instance, the building support structure 12 need not be overhead, but instead may be a wall of the building 11. The grid assembly 14 may also be formed of furring strips or other strips of wood or metal that are directly attached to the building support structure 12. Finally, the grid assembly 14 need not be planar, and may be curved, bent, or formed in any desired shape to achieve a specific appearance.

[00105] As illustrated in Figs. 5-8, the grille assemblies 100 may be attached to the grid assembly 14 by a variety of fastening means including screws, nails, rivets, or other known fasteners. In other implementations, the grille assemblies 100 may be attached via clips or brackets which engage the grid assembly 14. These clips may be designed to snap-fasten to the profile of the grid assembly 14 to facilitate installation. In yet other embodiments, the fastening means, including fasteners and clips, may attach directly to the building support structure 12 and the grid assembly 14 may be omitted entirely.

[00106] For example, Figs. 5 and 6 illustrate a clip 20, the clip 20 configured to couple the grid assembly 14 to a grille assemblies 100, securing the grille assemblies 100 in position. The clip 20 has a U-shaped profile including a base portion 21, lateral portions 22, and snap features 23 on the lateral portions 22. The snap features 23 engage the grid assembly 14 while the base portion 21 engages the grille assembly 100 to secure the grille assembly 100 to the grid assembly 14. The clips 20 may be installed after the grille assembly 100 is positioned adjacent the grid assembly 14 or may be preinstalled to the grille assembly 100 and may engage the grid assembly 14 as the grille assembly 100 is positioned adjacent the grid assembly.

[00107] Figs. 7 and 8 illustrate two alternate mounting configurations. In Fig. 7, furring strips 30 may be mounted to a building surface 31 such as a wall or ceiling. The furring strips 30 may form the grid assembly 14, and may be a series of parallel members or may be arranged as a series of parallel members and perpendicular members. The grille assembly 100 may be fastened to the furring strips 30 by fasteners 32 such as screws. In Fig. 8, fasteners 32 are used to directly couple the grille assembly 100 to the grid assembly 14. For instance, the fasteners 32 may be screws which are installed through a portion of the grille assembly 100 and engage the grid assembly 14.

[00108] Figs. 9-13 illustrate a single grille assembly 100. The grille assembly 100 extends from a proximal end 102 to a distal end 104. The grille assembly 100 comprises a plurality of slats 110, each of the slats 110 extending along a slat axis A- A. The slats 110 extend along their respective slat axes A-A from a first end 112 to a second end 114. The slats 110 are generally rectangular in cross-section with respect to the slat axis A-A, but may be alternate shapes and need not have a constant cross-section with respect to the slat axis A-A.

[00109] The slats 110 have a first major surface 116 and a second major surface 118 which extend in the vertical direction. The slats 110 also have a top edge 120 and a bottom edge 122, the first and second major surfaces 116, 118 extending between the top edge 120 and the bottom edge 122. Stated differently, the top edge 120 extends between the first and second major surfaces 116, 118 and the bottom edge 122 extends between the first and second major surfaces 116, 118. The slats 110 are elongate in a vertical direction which is perpendicular to the slat axis A-A, having a height which is greater than a width. Generally, the height between the top edge 120 and the bottom edge 122 is greater than the width of the slats 110 between the first and second major surfaces 116, 118. However, in other configurations, the width may be greater than the height as desired.

[00110] The grille assembly 100 further comprises a plurality of first cross-backer beams 130 and a plurality of second cross-backer beams 150. Each of the first cross-backer beams 130 and each of the second cross-backer beams 150 extend along a cross-beam axis B-B. Each of the cross-beam axes B-B is oriented substantially perpendicular to the slat axis A-A and extends through one of the pluralities of first or second cross-backer beams 130, 150. The pluralities of first and second cross-backer beams 130, 150 are spaced apart along the slat axis A-A. Optionally, the grille assembly 100 may be comprised exclusively of the plurality of first cross-backer beams 130 or may be comprised exclusively of the plurality of second crossbacker beams 150. In yet other implementations, the grille assembly 100 may utilize three or more types of cross-backer beams. No particular arrangement of cross-backer beams 130, 150 is required. In other words, there is no need to alternate first cross-backer beams 130 and second cross-backer beams 150. Any configuration may be utilized, including exclusively first or second cross-backer beams 130, 150.

[00111] Each of the cross-backer beams 130, 150 are spaced apart from one another to form a plurality of bays 190 between adjacent ones of the cross-backer beams 130, 150. Otherwise stated, the cross-backer beams 130, 150 are spaced apart along the slat axis A-A. Each bay 190 is formed by the space between the cross-backer beams 130, 150. The grille assembly 100 further comprises a plurality of angled backer beams 170. The plurality of angled backer beams 170 are arranged such that they are located within the bays 190. Optionally, a portion of the bays 190 receive an angled backer beam 170 while another portion of the bays 190 are free of angled backer beams 170. In other implementations, all or none of the bays 190 receive an angled backer beam 170. In yet other implementations, more than one type of angled backer beam may be utilized.

[00112] For reference, each of the bays 190 may be numbered from a proximal end 102 to a distal end 104 of the grille assembly 100. A first bay 190 may be the bay 190 which is closest to the proximal end 102, while an eighth bay 190 may be the bay 190 which is closest to the distal end 104. However, the number of bays 190 may vary as required and are not limited to eight bays 190. The grille assembly 100 incorporates angled backer beams 170 in each of the second through seventh bays 190. In other embodiments, angled backer beams 170 may be in greater or fewer bays 190 and need not be in adjacent bays 190.

[00113] Each of the angled backer beams 170 extend along a primary angled beam axis C-C. Each of the primary angled beam axes C-C extend obliquely to the slat axes A-A and the cross-beam axes B-B. Each of the angled backer beams 170 extend along the primary angled beam axis C-C from a proximal end 172 to a distal end 174. Each of the first and second crossbacker beams 130, 150 and the angled backer beams 170 is attached to one or more of the slats 110 via one or more fasteners 192. The fasteners 192 may be screws, staples, bolts, or any other known fastening device.

[00114] Preferably, the angled backer beams 170 abut one of the first cross-backer beams 130 and one of the second cross-backer beams 150. The angled backer beams 170 serve to provide triangulation of the grille assembly 100. Within each bay 190, a pair of triangles is defined by the cross-backer beams 130, 150, the angled backer beam 170, and the outermost slats 110. This increases rigidity of the grille assembly 100 and prevents movement of the cross-beam axes B-B with respect to the slat axes A-A. It also mitigates bowing and other distortion of the slats 110. The angled backer beams 170 are oriented so that the primary angled beam axes C-C are substantially parallel to each other. However, in other embodiments, the primary angled beam axes C-C may be at different angles. Furthermore, the angled backer beams 170 may not abut the first or second cross-backer beams 130, 150.

[00115] Each of the angled backer beams 170 is in contact with the top edges 120 of the slats 110 and preferably overlies all of the slats 110. The angled backer beams 170 are each fastened to at least two of the slats 110 by fasteners 192. Preferably, the angled backer beams 170 are fastened to the outermost slats 110. The angled backer beams 170 may be fastened to more than two slats 110 if desired. Optionally, the angled backer beams 170 may be fastened to the adjacent cross-backer beams 130, 150 via an interlock arrangement, fasteners, or any other known means, with the cross-backer beams 130, 150 being directly coupled and fastened to the slats 110.

[00116] The slats 110 may be formed of a variety of materials. These materials may include solid wood, composite wood, engineered wood, plywood, or combinations thereof. Alternately, the slats 110 may be formed of synthetic materials such as plastics, woven or nonwoven materials, foam materials, cloth materials, or combinations thereof. The cross-backer beams 130, 150 and the angled backer beams 170 may be formed of solid wood, composite wood, engineered wood, plywood, plastic, ceramic, metal, or combinations thereof. [00117] The grille assembly 100 may be attached to the grid assembly 14 by coupling the cross-backer beams 130, 150 to the grid assembly 14. Optionally, only the first crossbacker beams 130 or only the second cross-backer beams 150 may be coupled to the grid assembly 14. In yet other implementations, both the first and second cross-backer beams 130, 150 are coupled to the grid assembly 14. Either some or all of the cross-backer beams 130, 150 may be coupled to the grid assembly 14 as required.

[00118] Turning to Figs. 14-16, a first cross-backer beam 130 is illustrated. The first cross-backer beam 130 extends from a proximal end 132 to a distal end 134. The first crossbacker beam 130 has a first vertical surface 136, a second vertical surface 138, a top surface 140, and a bottom surface 142. The top and bottom surfaces 140, 142 extend from the first vertical surface 136 to the second vertical surface 138.

[00119] A plurality of notches 144 are formed into the bottom surface 142, each of the notches 144 having a notch depth Hl. The plurality of notches 144 are configured to receive the top edge 120 of the slats 110. Top portions of the slats 110 nest within the notches 144, the slats 110 having a height which is greater than the notch depth Hl . The first cross-backer beam 130 has a beam height H2 which is greater than the notch depth Hl. A plurality of fastener holes 146 extend from the top surface 140 through to the notches 144 to allow the passage of a fastener 192. Optionally, the fastener holes 146 may be countersunk, counterbored, or may be a plain or threaded hole of substantially constant diameter. One fastener hole 146 may be provided for each corresponding slat 110, or only a portion of the slats 110 may have corresponding fastener holes 146.

[00120] Figs. 17-19 illustrate an angled backer beam 170, the angled backer beam 170 extending from a proximal end 172 to a distal end 174. The angled backer beam 170 has a first vertical surface 176, a second vertical surface 178, a top surface 180, and a bottom surface 182. The top and bottom surfaces 180, 182 extend from the first vertical surface 176 to the second vertical surface 178. The angled backer beam 170 has a beam height H3 which may be less than the beam height H2 of the first cross-backer beams 130.

[00121] A plurality of fastener holes 186 extend from the top surface 180 to the bottom surface 182. As can be seen, the proximal end 172 and the distal end 174 are angled at an oblique angle with respect to the first and second vertical surfaces 176, 178. Like the fastener holes 146, the fastener holes 186 may be plain, threaded, counterbored, or countersunk holes. The fastener holes 186 are configured to align with a top edge 120 of a slat 110, while the proximal and distal ends 172, 174 are configured to abut the cross-backer beams 130, 150. The bottom surface 182 is planar and is in contact with the top edges 120 of the slats 110. The proximal and distal ends 172, 174 may not abut the cross-backer beams 130, 150 in other implementations.

[00122] Figs. 20-22 illustrate a second cross-backer beam 150. The second cross-backer beam 150 extends from a proximal end 152 to a distal end 154. The second cross-backer beam 150 has a first vertical surface 156, a second vertical surface 158, a top surface 160, and a bottom surface 162. The top and bottom surfaces 160, 162 extend from the first vertical surface 156 to the second vertical surface 158. The second cross-backer beam 150 has a beam height H4 which may be less than the beam height H2 of the first cross-backer beams 130 and equal to the beam height H3 of the angled backer beams 170.

[00123] A plurality of fastener holes 166 extend from the top surface 160 to the bottom surface 162. Like the fastener holes 146, the fastener holes 166 may be plain, threaded, counterbored, or countersunk holes. The fastener holes 166 are configured to align with a top edge 120 of a slat 110. In addition, mounting holes 168 are provided, which may be used to attach the second cross-backer beams 150 to the support structure 12, either directly or via the grid assembly 14. The bottom surface 162 is planar and is in contact with the top edges 120 of the slats 110.

[00124] Turning to Figs. 23-26, a second embodiment of a grille assembly 200 is illustrated. The grille assembly 200 is similar to the grille assembly 100 except as discussed below. The grille assembly 200 comprises a plurality of slats 110, first cross-backer beams 130, second cross-backer beams 150, and angled backer beams 170. As discussed above, bays 290 are formed by the space between the cross-backer beams 130, 150. No particular arrangement of cross-backer beams 130, 150 is required. In other words, there is no need to alternate first cross-backer beams 130 and second cross-backer beams 150. Any configuration may be utilized, including exclusively first or second cross-backer beams 130, 150.

[00125] For reference, each of the bays 290 may be numbered from a proximal end 202 to a distal end 204 of the grille assembly 200. A first bay 290 may be the bay 290 which is closest to the proximal end 202, while an eighth bay 290 may be the bay 290 which is closest to the distal end 204. However, the number of bays 290 may vary as required and are not limited to eight bays 290. The grille assembly 200 incorporates two angled backer beams 170, with one angled backer beam 170 in the second bay 290 and a second angled backer beam 170 in the seventh bay 290.

[00126] Turning to Figs. 27-31, a third embodiment of a grille assembly 300 is illustrated. The grille assembly 300 is similar to the grille assembly 100, with the exception of changes to the angled backer beams as will be discussed in greater detail. The grille assembly 300 comprises aplurality of slats 110, first cross-backer beams 130, second cross-backer beams 150, and angled backer beams 370. As discussed above, bays 390 are formed by the space between the cross-backer beams 130, 150. No particular arrangement of cross-backer beams 130, 150 is required. In other words, there is no need to alternate first cross-backer beams 130 and second cross-backer beams 150. Any configuration may be utilized, including exclusively first or second cross-backer beams 130, 150.

[00127] For reference, each of the bays 390 may be numbered from a proximal end 302 to a distal end 304 of the grille assembly 300. A first bay 390 may be the bay 390 which is closest to the proximal end 302, while an eighth bay 390 may be the bay 390 which is closest to the distal end 304. However, the number of bays 390 may vary as required and are not limited to eight bays 390. The grille assembly 300 incorporates two angled backer beams 370 in each of the second through seventh bays 390. However, in other implementations all of the bays 390 or fewer than six bays 390 may receive angled backer beams 370. In yet other implementations, not all bays 390 that receive angled backer beams 370 may receive two angled backer beams 370. In yet other implementations, the angled backer beams 370 may be mixed with other styles of angled backer beams such as the angled backer beams 170 described above.

[00128] A first portion of the plurality of angled backer beams 370 extend along a primary angled beam axis C-C while a second portion of the plurality of angled backer beams 370 extend along a secondary angled beam axis D-D. The first portion of the plurality of angled backer beams 370 may be referred to as primary angled backer beams while the second portion of the angled backer beams 370 may be referred to as secondary angled backer beams. Each of the primary angled beam axes C-C extend obliquely to the slat axes A-A and the cross-beam axes B-B. Each of the secondary angled beam axes D-D extend obliquely to the slat axes A- A, the cross-beam axes B-B, and the primary angled beam axes C-C. Each of the angled backer beams 370 extend along their respective primary or secondary angled beam axis C-C, D-D from a proximal end 372 to a distal end 374. Each of the first and second cross-backer beams 130, 150 and the angled backer beams 370 is attached to one or more of the slats 110 via one or more fasteners 192. The fasteners 192 may be screws, staples, bolts, or any other known fastening device.

[00129] The angled backer beams 370 may abut one of the first cross-backer beams 130 and one of the second cross-backer beams 150. The angled backer beams 370 serve to provide triangulation of the grille assembly 300. Within each bay 390, three triangles are defined by the cross-backer beams 130, 150, the angled backer beams 370, and the outermost slats 110. This increases rigidity of the grille assembly 300 and prevents movement of the cross-beam axes B-B with respect to the slat axes A- A. It also mitigates bowing and other distortion of the slats 110. The angled backer beams 370 are oriented so that the primary angled beam axes C- C are substantially parallel to each other and the secondary angled beam axes D-D are substantially parallel to each other. However, in other embodiments, the primary angled beam axes C-C may be at different angles. Similarly, the secondary angled beam axes D-D may be at different angles. Optionally, the angled backer beams 370 may abut two of the first crossbacker beams 130 or two of the second cross-backer beams 150. Two of the angled backer beams 370, when arranged as a primary and a secondary backer angled backer beam within the same bay 390, form a V-shaped brace assembly 391. The resulting V-shaped brace assembly 391 has an apex 392 that points toward a transverse centerline E-E of the grille assembly 300. [00130] Each of the angled backer beams 370 is in contact with the top edges 120 of the slats 110 and preferably overlies at least two of the slats 110. The angled backer beams 370 are each fastened to at least two of the slats 110 by fasteners 192. The angled backer beams 370 may be fastened to more than two slats 110 if desired. Optionally, the angled backer beams 370 may be fastened to the adjacent cross-backer beams 130, 150 via an interlock arrangement, fasteners, or any other known means, with the cross-backer beams 130, 150 being directly coupled and fastened to the slats 110. The cross-backer beams 130, 150 and the angled backer beams 370 may be formed of solid wood, composite wood, engineered wood, plywood, plastic, ceramic, metal, or combinations thereof.

[00131] Figs. 32-34 illustrate an angled backer beam 370, the angled backer beam 370 extending from a proximal end 372 to a distal end 374. The angled backer beam 370 has a first vertical surface 376, a second vertical surface 378, a top surface 380, and a bottom surface 382. The top and bottom surfaces 380, 382 extend from the first vertical surface 376 to the second vertical surface 378. The angled backer beam 370 has a beam height H3 which may be less than the beam height H2 of the first cross-backer beams 130.

[00132] A plurality of fastener holes 386 extend from the top surface 380 to the bottom surface 382. As can be seen, the proximal end 372 and the distal end 374 are angled at an oblique angle with respect to the first and second vertical surfaces 376, 378. Like the fastener holes 146, the fastener holes 386 may be plain, threaded, counterbored, or countersunk holes. The fastener holes 386 are configured to align with a top edge 120 of a slat 110, while the proximal and distal ends 372, 374 are configured to abut the cross-backer beams 130, 150. The bottom surface 382 is planar and is in contact with the top edges 120 of the slats 110. The angled backer beams 370 are symmetrical so that they can be utilized for both the primary and the secondary angled backer beams, but in other embodiments the angled backer beams 370 may differ between the primary and secondary angled backer beams. Optionally, the proximal and distal ends 372, 374 may not abut the cross-backer beams 130, 150

[00133] Figs. 35-38 illustrate a fourth embodiment of a grille assembly 400. The grille assembly 400 is similar to the grille assembly 100 except as discussed below. The grille assembly 400 comprises a plurality of slats 110, first cross-backer beams 130, second crossbacker beams 150, and angled backer beams 370. As discussed above, bays 490 are formed by the space between the cross-backer beams 130, 150. No particular arrangement of crossbacker beams 130, 150 is required. In other words, there is no need to alternate first crossbacker beams 130 and second cross-backer beams 150. Any configuration may be utilized, including exclusively first or second cross-backer beams 130, 150.

[00134] For reference, each of the bays 490 may be numbered from a proximal end 402 to a distal end 404 of the grille assembly 400. A first bay 490 may be the bay 490 which is closest to the proximal end 402, while an eighth bay 490 may be the bay 490 which is closest to the distal end 404. However, the number of bays 490 may vary as required and are not limited to eight bays 490. The grille assembly 400 incorporates two angled backer beams 370 in each of the second and seventh bays 490.

[00135] Turning to Figs. 39-42, a fifth embodiment of a grille assembly 500 is illustrated. The grille assembly 500 is similar to the grille assembly 100, with the exception of changes to the angled backer beams as will be discussed in greater detail. The grille assembly 500 comprises aplurality of slats 110, first cross-backer beams 130, second cross-backer beams 150, primary angled backer beams 570, and secondary angled backer beams 580. As discussed above, bays 590 are formed by the space between the cross-backer beams 130, 150. No particular arrangement of cross-backer beams 130, 150 is required. In other words, there is no need to alternate first cross-backer beams 130 and second cross-backer beams 150. Any configuration may be utilized, including exclusively first or second cross-backer beams 130, 150.

[00136] For reference, each of the bays 590 may be numbered from a proximal end 502 to a distal end 504 of the grille assembly 500. A first bay 590 may be the bay 590 which is closest to the proximal end 502, while an eighth bay 590 may be the bay 590 which is closest to the distal end 504. However, the number of bays 590 may vary as required and are not limited to eight bays 590. The grille assembly 500 incorporates primary and secondary angled backer beams 570, 580 in each of the second through seventh bays 590. However, in other implementations all of the bays 590 or fewer than six bays 590 may receive first and second angled backer beams 570, 580. In yet other implementations, not all bays 590 that receive angled backer beams 570, 580 may receive two angled backer beams 570, 580. In yet other implementations, the angled backer beams 570, 580 may be mixed with other styles of angled backer beams such as the angled backer beams 170 described above. In yet further variations, only one or the other of the angled backer beams 570, 580 may be used in some of the bays 590.

[00137] A plurality of the primary angled backer beams 570 extend along a plurality of primary angled beam axes C-C while a plurality of the secondary angled backer beams 580 extend along a plurality of secondary angled beam axes D-D. Each of the primary angled beam axes C-C extend obliquely to the slat axes A-A and the cross-beam axes B-B. Each of the secondary angled beam axes D-D extend obliquely to the slat axes A-A and the cross-beam axes B-B. The secondary angled beam axes D-D may be perpendicular or oblique to the primary angled beam axes C-C. Each of the primary angled backer beams 570 extend along a primary angled beam axis C-C from a proximal end 571 to a distal end 572. Each of the secondary angled backer beams 580 extend along a primary angled beam axis D-D from a proximal end 581 to a distal end 582. Each of the first and second cross-backer beams 130, 150 and the angled backer beams 570, 580 is attached to one or more of the slats 110 via one or more fasteners 192. The fasteners 192 may be screws, staples, bolts, or any other known fastening device.

[00138] The angled backer beams 570, 580 may abut one of the first cross-backer beams

130 and one of the second cross-backer beams 150. The angled backer beams 570, 580 serve to provide triangulation of the grille assembly 500. Within each bay 590, four triangles are defined by the cross-backer beams 130, 150, the angled backer beams 570, 580, and the outermost slats 110. This increases rigidity of the grille assembly 500 and prevents movement of the cross-beam axes B-B with respect to the slat axes A-A. It also mitigates bowing and other distortion of the slats 110. The angled backer beams 570, 580 are oriented so that the primary angled beam axes C-C are substantially parallel to each other and the secondary angled beam axes D-D are substantially parallel to each other. However, in other embodiments, the primary angled beam axes C-C may be at different angles. Similarly, the secondary angled beam axes D-D may be at different angles. Optionally, the angled backer beams 570, 580 may abut two of the first cross-backer beams 130 or two of the second cross-backer beams 150.

[00139] Each of the angled backer beams 570, 580 is in contact with the top edges 120 of the slats 110 and preferably overlies all of the slats 110. The angled backer beams 570, 580 are each fastened to at least two of the slats 110 by fasteners 192. The angled backer beams 570, 580 may be fastened to more than two slats 110 if desired. The primary angled backer beams 570 interlock with the secondary angled backer beams 580 as will be discussed in greater detail below. Optionally, the angled backer beams 570, 580 may be fastened to each other or the adjacent cross-backer beams 130, 150 via an interlock arrangement, fasteners, or any other known means, with the cross-backer beams 130, 150 being directly coupled and fastened to the slats 110. The cross-backer beams 130, 150 and the angled backer beams 570, 580 may be formed of solid wood, composite wood, engineered wood, plywood, plastic, ceramic, metal, or combinations thereof.

[00140] Figs. 43-45 illustrate a primary angled backer beam 570, the primary angled backer beam 570 extending from a proximal end 571 to a distal end 572. The primary angled backer beam 570 has a first vertical surface 573, a second vertical surface 574, a top surface 575, and a bottom surface 576. The top and bottom surfaces 575, 576 extend from the first vertical surface 573 to the second vertical surface 574. The primary angled backer beam 570 has a beam height H5 which may be less than the beam height H2 of the first cross-backer beams 130 and equal to the beam height H4 of the second cross-backer beams 150.

[00141] A plurality of fastener holes 577 extend from the top surface 575 to the bottom surface 576. As can be seen, the proximal end 571 and the distal end 572 are angled at an oblique angle with respect to the first and second vertical surfaces 573, 574. Like the fastener holes 146, the fastener holes 577 may be plain, threaded, counterbored, or countersunk holes. The fastener holes 577 are configured to align with a top edge 120 of a slat 110, while the proximal and distal ends 571, 572 are configured to abut the cross-backer beams 130, 150. The bottom surface 576 is planar and is in contact with the top edges 120 of the slats 110. The primary angled backer beams 570 also incorporate a notch 578 formed in the top surface 575 which has a notch depth H6 that is approximately half of the beam height H5. In other embodiments, the notch depth H6 may be greater or less than the beam height H5. Optionally, the proximal and distal ends 571, 572 may not abut the cross-backer beams 130, 150.

[00142] Figs. 46-48 illustrate a secondary angled backer beam 580, the secondary angled backer beam 580 extending from a proximal end 581 to a distal end 582. The secondary angled backer beam 580 has a first vertical surface 583, a second vertical surface 584, a top surface 585, and a bottom surface 586. The top and bottom surfaces 585, 586 extend from the first vertical surface 583 to the second vertical surface 584. The secondary angled backer beam 580 has a beam height H7 which may be less than the beam height H2 of the first cross-backer beams 130 and equal to the beam height H4 of the second cross-backer beams 150. [00143] A plurality of fastener holes 587 extend from the top surface 585 to the bottom surface 586. As can be seen, the proximal end 581 and the distal end 582 are angled at an oblique angle with respect to the first and second vertical surfaces 583, 584. Like the fastener holes 146, the fastener holes 587 may be plain, threaded, counterbored, or countersunk holes. The fastener holes 587 are configured to align with a top edge 120 of a slat 110, while the proximal and distal ends 581, 582 are configured to abut the cross-backer beams 130, 150. The bottom surface 586 is planar and is in contact with the top edges 120 of the slats 110, with the exception of a notch 588. Optionally, the proximal and distal ends 581, 582 may not abut the cross-backer beams 130, 150.

[00144] The secondary angled backer beams 580 also incorporate the notch 588 formed in the bottom surface 586 which has a notch depth H8 that is approximately half of the beam height H7. In other embodiments, the notch depth H8 may be greater or less than the beam height H7. The notch 588 and the notch 578 allow the primary and secondary angled backer beams 570, 580 to cross without interference. In other embodiments, the secondary angled backer beam 580 may be formed in two pieces instead of forming notches 578, 588 into the primary and secondary angled backer beams 570, 580. The pairing of the primary and secondary angled backer beams 570, 580 forms an X-shaped brace assembly 591 within the bay 590. The intersection of the X-shaped brace assembly is aligned with a transverse centerline E-E of the grille assembly.

[00145] Figs. 49-52 illustrate a sixth embodiment of a grille assembly 600. The grille assembly 600 is similar to the grille assembly 100 except as discussed below. The grille assembly 600 comprises a plurality of slats 110, first cross-backer beams 130, second crossbackerbeams 150, primary angled backer beams 570, and secondary angled backer beams 580. As discussed above, bays 690 are formed by the space between the cross-backer beams 130, 150. No particular arrangement of cross-backer beams 130, 150 is required. In other words, there is no need to alternate first cross-backer beams 130 and second cross-backer beams 150. Any configuration may be utilized, including exclusively first or second cross-backer beams 130, 150.

[00146] For reference, each of the bays 690 may be numbered from a proximal end 602 to a distal end 604 of the grille assembly 600. A first bay 690 may be the bay 690 which is closest to the proximal end 602, while an eighth bay 690 may be the bay 690 which is closest to the distal end 604. However, the number of bays 690 may vary as required and are not limited to eight bays 690. The grille assembly 600 incorporates primary and secondary angled backer beams 570, 580 in each of the second and seventh bays 690. The other bays 690 are free of angled backer beams 570, 580.

[00147] As can be seen, the angled backer beams may be arranged in some or all of the bays of the various embodiments disclosed above. Furthermore, the number of bays may be varied as desired. In some implementations, N number of bays may be formed sequentially along a length of the grille assembly. The first bay is at the proximal end while the Nth bay is at the distal end. In one implementation, where N is greater than or equal to five, one of the angled backer beams is positioned in each of the second bay and the N-lth bay. The remaining bays are free of any angled backer beams.

[00148] In another implementation, N number of bays are formed sequentially along a length of the grille assembly. The first bay is at the proximal end while the Nth bay is at the distal end. In one implementation, N is greater than or equal to four. One of the primary angled backer beams is positioned in each of the second and N-lth bay. Each of the first and Nth bay are free of any angled backer beams.

[00149] In yet another implementation, N number of bays are formed along the length of the grille assembly starting with a first bay at a proximal end of the grille assembly and ending with an Nth bay at a distal end of the grille assembly. N is greater than or equal to three. Where N is an odd number, the (N/2 + 0.5)th bay is free of any angled backer beams and where N is an even number, the (N/2)th bay and the (N/2+l)th bay are free of any angled backer beams.

[00150] Figs. 53-56 illustrate a seventh embodiment of a grille assembly 700 as may be used in the surface covering system 10. The grille assembly 700 extends from a proximal end 702 to a distal end 704. The grille assembly 700 comprises a plurality of slats 110 identical to the slats 110 discussed above. Each of the slats 110 extend along a slat axis A-A. The slats 110 extend along their respective slat axes A-A from a first end 112 to a second end 114. The slats 110 are generally rectangular in cross-section with respect to the slat axis A-A, but may be alternate shapes and need not have a constant cross-section with respect to the slat axis A- A.

[00151] The slats 110 have a first major surface 116 and a second major surface 118 which extend in the vertical direction. The slats 110 also have a top edge 120 and a bottom edge 122, the first and second major surfaces 116, 118 extending between the top edge 120 and the bottom edge 122. Stated differently, the top edge 120 extends between the first and second major surfaces 116, 118 and the bottom edge 122 extends between the first and second major surfaces 116, 118. The slats 110 are elongate in a vertical direction which is perpendicular to the slat axis A-A, having a height which is greater than a width. Generally, the height between the top edge 120 and the bottom edge 122 is greater than the width of the slats 110 between the first and second major surfaces 116, 118. However, in other configurations, the width may be greater than the height as desired.

[00152] The grille assembly 700 further comprises a plurality of first cross-backer beams 730 and a plurality of second cross-backer beams 750. Each of the first cross-backer beams 730 and each of the second cross-backer beams 750 extend along a cross-beam axis B-B. Each of the cross-beam axes B-B is oriented substantially perpendicular to the slat axis A-A and extends through one of the pluralities of first or second cross-backer beams 730, 750. The pluralities of first and second cross-backer beams 730, 750 are spaced apart along the slat axis A-A. Optionally, the grille assembly 700 may be comprised exclusively of the plurality of first cross-backer beams 730 or may be comprised exclusively of the plurality of second crossbacker beams 750. In yet other implementations, the grille assembly 700 may utilize three or more types of cross-backer beams. No particular arrangement of cross-backer beams 730, 750 is required. In other words, there is no need to alternate first cross-backer beams 730 and second cross-backer beams 750. Any configuration may be utilized, including exclusively first or second cross-backer beams 730, 750.

[00153] Each of the cross-backer beams 730, 750 are spaced apart from one another to form a plurality of bays 790 between adjacent ones of the cross-backer beams 730, 750. Otherwise stated, the cross-backer beams 730, 750 are spaced apart along the slat axis A-A. Each bay 790 is formed by the space between the cross-backer beams 730, 750. For reference, each of the bays 790 may be numbered from a proximal end 702 to a distal end 704 of the grille assembly 700. A first bay 790 may be the bay 790 which is closest to the proximal end 702, while an eighth bay 790 may be the bay 790 which is closest to the distal end 704. However, the number of bays 790 may vary as required and are not limited to eight bays 790.

[00154] Each of the first and second cross-backer beams 730, 750 is attached to one or more of the slats 110 via one or more fasteners 192. The fasteners 192 may be screws, staples, bolts, or any other known fastening device. The slats 110 may be formed of a variety of materials. These materials may include solid wood, composite wood, engineered wood, plywood, or combinations thereof. Alternately, the slats 110 may be formed of synthetic materials such as plastics, woven or non-woven materials, foam materials, cloth materials, or combinations thereof. The cross-backer beams 730, 750 may be formed of solid wood, composite wood, engineered wood, plywood, plastic, ceramic, metal, or combinations thereof. [00155] The grille assembly 700 may be attached to the grid assembly 14 by coupling the cross-backer beams 730, 750 to beams of the grid assembly 14. Optionally, only the first cross-backer beams 730 or only the second cross-backer beams 750 may be coupled to the grid assembly 14. In yet other implementations, both the first and second cross-backer beams 730, 750 are coupled to the grid assembly 14. Either some or all of the cross-backer beams 730, 750 may be coupled to the grid assembly 14 as required.

[00156] A transverse center plane is located at a midpoint between the proximal and distal ends 702, 704 of the grille assembly 700. The transverse center plane is perpendicular to each of the slat axes A- A. In some implementations, one of the first or second cross-backer beams 730, 750 are located along the transverse center plane, the cross beam axis B-B of one of the first or second cross-backer beams 730, 750 lying within the transverse center plane and being coincident with the transverse center plane. In yet other embodiments, the transverse center plane may be equidistant between two of the cross-backer beams 730, 750. The first and second cross-backer beams 730, 750 may be arranged in a symmetric pattern about the transverse center plane. The first and second cross-backer beams 730, 750 may be arranged in an alternating pattern along the length of the slats 110, or may be arranged in any other pattern along the length of the slats 110.

[00157] Turning to Figs. 57-59, a first cross-backer beam 730 is illustrated. The first cross-backer beam 730 extends from a proximal end 732 to a distal end 734. The first crossbacker beam 730 has a first vertical surface 736, a second vertical surface 738, a top surface 740, and a bottom surface 742. The top and bottom surfaces 740, 742 extend from the first vertical surface 736 to the second vertical surface 738.

[00158] A plurality of notches 744 are formed into the bottom surface 742, each of the notches 744 having a notch depth H9 measured from a floor surface 745 to the bottom surface 742. The plurality of notches 744 are configured to receive the top edge 120 of the slats 110. Preferably, the top edges 120 of the slats 110 are substantially co-planar, the top edges 120 resting against the floor surfaces 745 of the first cross-backer beam 730. Furthermore, the bottom edges 122 of the slats 110 are substantially coplanar.

[00159] Top portions of the slats 110 nest within the notches 744, the slats 110 having a height which is greater than the notch depth H9. The first cross-backer beam 730 has a beam height H10 which is greater than the notch depth H9. A plurality of fastener holes may extend from the top surface 740 through to the notches 744 to allow the passage of a fastener 192. Optionally, the fastener holes may be countersunk, counterbored, or may be a plain or threaded hole of substantially constant diameter. One fastener hole may be provided for each corresponding slat 110, or only a portion of the slats 110 may have corresponding fastener holes. In addition, mounting holes may be provided to attach the first cross-backer beams 730 to the support structure 12, either directly or via the grid assembly 14.

[00160] Figs. 60-62 illustrate a second cross-backer beam 750. The second cross-backer beam 750 extends from a proximal end 752 to a distal end 754. The second cross-backer beam 750 has a first vertical surface 756, a second vertical surface 758, a top surface 760, and a bottom surface 762. The top and bottom surfaces 760, 762 extend from the first vertical surface 756 to the second vertical surface 758. The second cross-backer beam 750 has a beam height H12 which may be less than the beam height H10 of the first cross-backer beams 730.

[00161] A plurality of notches 764 are formed into the bottom surface 762, each of the notches 764 having a notch depth Hl 1 measured from a floor surface 765 to the bottom surface 762. The plurality of notches 764 are configured to receive the top edge 120 of the slats 110. Preferably, the top edges 120 of the slats 110 are substantially co-planar, the top edges 120 resting against the floor surfaces 765 of the second cross-backer beam 750. Furthermore, the bottom edges 122 of the slats 110 are substantially coplanar. Preferably, the floor surfaces 745, 765 of the first and second cross-backer beams 730, 750 are substantially coplanar.

[00162] Top portions of the slats 110 nest within the notches 764, the slats 110 having a height which is greater than the notch depth Hll. The second cross-backer beam 750 has a beam height H12 which is greater than the notch depth Hl 1. A plurality of fastener holes may extend from the top surface 760 through to the notches 764 to allow the passage of a fastener 192. Optionally, the fastener holes may be countersunk, counterbored, or may be a plain or threaded hole of substantially constant diameter. One fastener hole may be provided for each corresponding slat 110, or only a portion of the slats 110 may have corresponding fastener holes. In addition, mounting holes may be provided, which may be used to attach the second cross-backer beams 750 to the support structure 12, either directly or via the grid assembly 14. [00163] In some embodiments, the top surfaces 740 of the first cross-backer beams 730 are substantially coplanar. In other embodiments, the top surfaces 760 of the second crossbacker beams 750 are substantially coplanar. In yet other implementations, the top surfaces 740, 760 of both the first and second cross-backer beams 730, 750 are substantially coplanar.

[00164] Preferably, the notch depth Hl 1 of the second cross-backer beams 750 is greater than the notch depth H9 of the first cross-backer beams 730. Preferably, the beam height H12 of the second cross-backer beams 750 is substantially equal to the beam height H10 of the first cross-backer beams 730. [00165] Each of the slats has a height as measured from the bottom edge 122 to the top edge 120 as discussed above. Preferably, a ratio between the notch depth Hl 1 to the height of the slats as is equal to or greater than 0.35:1. Further preferably, the ratio of the notch depth Hl 1 to the height of the slats is equal to or greater than 0.5:1.

[00166] Turning to Figs. 63-65, an alternate embodiment of the second cross backer beam 750A is illustrated. The second cross-backer beams 750A are equivalent to the crossbacker beams 750 except as discussed below. The reference numerals for the second cross backer beams 750A are identical except as noted. The second cross backer beams 750A have a top surface 760 and an opposite bottom surface 762. A plurality of notches 764 are formed into the bottom surface 762 of the second cross backer beams 750A. Each notch 764 has a floor surface 765, a notch depth Hl 1 measured from the floor surface 765 to the bottom surface 762. Each notch 764 also has a pair of opposing sidewall surfaces 766 which extend between the bottom surface 762 and the floor surface 765.

[00167] A radiused comer 767 is formed at each intersection between the sidewall surface 766 and the floor surface 765. Thus, two radiused corners 767 are formed in each notch 764. In alternate configurations, the radiused corners 767 may be formed in only a portion of the notches 764. Thus, only one or two of the notches 764 may have radiused comers 767. Optionally, only a single radiused comer 767 may be formed in each notch 764. The radiused comers 767 may have a radius of 0.030 inches (0.762 mm), 0.060 inches (1.524 mm), or another value as desired.

[00168] A plurality of teeth 768 are formed by the spaces between adjacent notches 764. Additional teeth 768 are formed between outermost notches 764 and proximal and distal ends 752, 754 of the second cross-backer beam 750A. As can be seen, the outermost teeth 768 have a width which is less than the inner teeth 768. The outermost teeth 768 are preferably less than or equal to half of the width of the inner teeth 768.

[00169] Turning to Figs. 66-69, another alternate embodiment of the second cross backer beam 750B is illustrated. The second cross-backer beams 750B are equivalent to the crossbacker beams 750 except as discussed below. The reference numerals for the second cross backer beams 750B are identical except as noted. The second cross backer beams 750B have a top surface 760 and an opposite bottom surface 762. A plurality of notches 764 are formed into the bottom surface 762 of the second cross backer beams 750B. Each notch 764 has a floor surface 765, a notch depth Hl 1 measured from the floor surface 765 to the bottom surface 762. Each notch 764 also has a pair of opposing sidewall surfaces 766 which extend between the bottom surface 762 and the floor surface 765. [00170] A radiused comer 767 is formed at an intersection between the sidewall surface 766 and the floor surface 765 on each of the two outermost notches 764. However, the radiused comer 767 is only formed immediately adjacent one of the sidewall surfaces 766 of the outermost notches 764. In particular, the radiused comer 767 is formed between the sidewall surface 766 nearest the proximal end 752 and the floor surface 765. Similarly, the radiused comer 767 is formed between the sidewall surface 766 nearest the distal end 754 and the floor surface 765. The other sidewall surfaces 766 in the outermost notches 764 do not have radiused comers 767 between the sidewall surfaces 766 and the floor surfaces 765. The sidewall surfaces 766 in the remaining notches 764 do not have radiused comers 767. In other combinations, the outermost notches 764 may have two radiused comers 767 while none of the remaining notches 764 have radiused corners 767. The radiused comers 767 may have a radius of 0.030 inches (0.762 mm), 0.060 inches (1.524 mm), or another value as desired.

[00171] A plurality of teeth 768 are formed by the spaces between adjacent notches 764. Additional teeth 768 are formed between outermost notches 764 and proximal and distal ends 752, 754 of the second cross-backer beam 750B. As can be seen, the outermost teeth 768 have a width which is less than the inner teeth 768. The outermost teeth 768 are preferably less than or equal to half of the width of the inner teeth 768.

[00172] Figs. 70-73 illustrate an eighth embodiment of a grille assembly 800. The grille assembly 800 is similar to the grill assembly 700 except as discussed below. The grille assembly comprises a plurality of slats 110, a plurality of first cross-backer beams 830, and a plurality of second cross-backer beams 750. Bays 890 are formed by the space between the cross-backer beams 830, 750. No particular arrangement of cross-backer beams 830, 750 is required. In other words, there is no need to alternate first cross-backer beams 830 and second cross-backer beams 750. Any configuration may be utilized, including exclusively first or second cross-backer beams 830, 850.

[00173] For reference, each of the bays 890 may be numbered from a proximal end 802 to a distal end 804 of the grille assembly 800. A first bay 890 may be the bay 890 which is closest to the proximal end 802, while an eighth bay 890 may be the bay 890 which is closest to the distal end 804. However, the number of bays 890 may vary as required and are not limited to eight bays 890.

[00174] Figs. 74-76 illustrate a first cross-backer beam 830. The first cross-backer beam 830 extends from a proximal end 832 to a distal end 834. The first cross-backer beam 830 has a first vertical surface 836, a second vertical surface 838, a top surface 840, and a bottom surface 842. The top and bottom surfaces 840, 842 extend from the first vertical surface 836 to the second vertical surface 838. The first cross-backer beam 830 has a beam height H13 which may be less than the beam height H12 of the second cross-backer beams 750.

[00175] A plurality of fastener holes may extend from the top surface 840 to the bottom surface 842. Like the fastener holes 146, the fastener holes may be plain, threaded, counterbored, or countersunk holes. The fastener holes may be configured to align with a top edge 120 of a slat 110. In addition, mounting holes 848 are provided, which may be used to attach the first cross-backer beams 830 to the support structure 12, either directly or via the grid assembly 14. The bottom surface 842 is planar and is in contact with the top edges 120 of the slats 110.

[00176] Turning to Figs. 77-80, a ninth embodiment of a grille assembly 900 is illustrated. The grille assembly 900 is similar to the grille assembly 700 except as discussed below. The grille assembly 900 comprises a plurality of slats 110 and a plurality of second cross-backer beams 750. As discussed above, bays 990 are formed by the space between the cross-backer beams 750. This configuration illustrates that only a single type of cross-backer beam may be utilized if so desired.

[00177] For reference, each of the bays 990 may be numbered from a proximal end 902 to a distal end 904 of the grille assembly 900. A first bay 990 may be the bay 990 which is closest to the proximal end 902, while an eighth bay 990 may be the bay 990 which is closest to the distal end 904. However, the number of bays 990 may vary as required and are not limited to eight bays 990.

[00178] Example 1

[00179] A series of tests were performed using grille assemblies according to the first through sixth embodiments. A plurality of slats 110 which had a bow were selected to evaluate how different configurations reduced or eliminated bow in the slats 110. Twelve slats 110 having a bow were selected and divided into three groups of slats 110. Each slat 110 was eight feet long and each grille assembly utilized eight bays. Each of the three groups of slats had approximately equal bow as shown in Table 1 below. Bow is measured as a maximum displacement from a theoretical plane drawn between the proximal and distal ends of the slat.

- Zi Table 1. Bowed Slat Sets

[00180] A series of grille assemblies were assembled with the bow of the slats 110 facing the same direction to provide the greatest potential for bowing of the grille assembly. During assembly, the slats 110 were straightened using spacer blocks between the slats 110 and clamps to hold the slats 110 in the straightened position. The cross-backer beams and the angled backer beams were assembled with screws while the slats 110 were held in the straightened position. Subsequent to assembly, the slats 110 were released and the bow was measured.

[00181] Bow measurements were made on each grille assembly after the clamps and spacer blocks were removed. With the grille assemblies oriented so that the slats 110 faced up and the cross-backer beams were resting against a flat surface, a straight edge was placed against the face of the slats 110 on the concave side of the grille assembly, and the gap between the straight edge and the slat 110 at the concave side of the grille assembly was measured at the center of the slats (4 feet from both the proximal and distal ends), using a ruled scale. All measurements were made in 32nds of inches.

[00182] For a portion of the configurations, the grille assembly was turned on one side, supported it by blocks at the proximal and distal ends, and with the concave side up. This way, the weight of the grille assembly itself increased the bow. In a further test, approximately 26 pounds of steel weights were added to the center of the grille assembly span, to stress the grille assembly even more. The bow of the grille assembly was measured in each of these conditions. [00183] In test case one, slat set A was used to assemble a grille assembly which was free of angled backer beams. The cross-backer beams were exclusively of the second crossbacker beam 150 style and were free of notches. In test case two, slat set B was used to assemble a grille assembly which utilized an angled backer beam in all eight bays of the grille assembly. The angled backer beams utilized were the angled backer beams 170 as utilized in the first and second embodiments. In test cases four through seven the angled backer beams 170 were removed two at a time starting from the center pair and moving outward. In test case seven, no angled backer beams 170 remained, resulting in a configuration identical to test case one, except for the use of slat set B. Exclusively the second cross-backer beams 150 were utilized for test cases two through seven.

[00184] For test cases eight through fourteen, grille assemblies were assembled utilizing exclusively the second cross-backer beams 150 and angled backer beams 170 in different combinations of bays. Slat set B were utilized for these tests. In test case eight, bays 4 and 5 had angled backer beams 170 while the remaining bays were free of angled backer beams 170. In test case nine, bays 1, 4, 5, and 8 had angled backer beams 170 while the remaining bays were free of angled backer beams 170. In test case ten, bays 1 and 8 had angled backer beams 170 while the remaining bays were free of angled backer beams 170.

[00185] In test case eleven, bays 2 and 7 had angled backer beams 170 while the remaining bays were free of angled backer beams 170. In test case twelve, bays 3 and 6 had angled backer beams 170 while the remaining bays were free of angled backer beams 170. In test case thirteen, bays 2 and 7 had angled backer beams 170 while the remaining bays were free of angled backer beams 170. In test case fourteen, bays 1 and 8 had angled backer beams 170 while the remaining bays were free of angled backer beams 170. In each of test cases three through fourteen, the grille assembly was adjusted using the spacer blocks and clamps to achieve the straightest possible grille assembly and reset the grille assembly to a baseline condition.

[00186] In test case fifteen, a grille assembly was prepared utilizing exclusively the first cross-backer beams 130 and no angled backer beams 170. The first cross-backer beams 130 utilized a notch depth of 0.5 inches. Test case fifteen utilized slat set C. Table 2 lists the bow results of the fifteen test cases. The “Normal” column reflects those measurements made with the slats 110 facing upward and the cross-backer beams 130, 150 on a flat surface. The “On Edge” column reflects those measurements made with the slats 110 supported by blocks at the proximal and distal ends and the concave side of the slats 110 facing up. The “W/ Weight” column reflects the orientation used in the “On Edge” tests with approximately 26 pounds added at the center of the uppermost slat 110 as discussed above. Table 2. Bow of Various Grille Constructions

[00187] As can be seen from Table 2, test case one resulted in a normal bow of 15/32 inch, which is comparable to the average bow of the slats 110 from slat set A. Putting the grille assembly on its side and adding weight markedly increased the bow. This is believed to be due to the fact that the second cross-backer beams 150 had very little ability to stiffen the grille assembly or straighten the slats 110.

[00188] In test cases two through seven, the angled backer beams 170 were utilized in the combinations listed. However, test case three was performed subsequent to the on edge and with weight tests performed on test case two. This showed that the deflection in the normal orientation increased due to the on edge and with weight testing. However, removal of angled backer beams 170 had comparatively little effect on the results. In fact, the bow did not meaningfully increase until the angled backer beams 170 were removed from the second through seventh bays. When all angled backer beams 170 were removed for test case seven, the bow approximately reflected the average of slat set B, confirming the results from test case one.

[00189] Test cases eight through fourteen illustrated that angled backer beams 170 in bays 2 and 7 have the greatest impact on reducing bow of the grille assemblies. Angled backer beams 170 in bays 1, 4, 5, and 8 or angled backer beams 170 in bays 1 and 8 achieve a similar results but are slightly less effective than angled backer beams 170 in bays 2 and 7 alone. Angled backer beams 170 in bays 2 and 7 are also more effective than angled backer beams 170 in bays 1 and 8 at resisting bow in the on edge and with weight tests.

[00190] In test case fifteen, it was shown that utilizing first cross-backer beams 130 having notches therein aids in reducing bow. Though less effective than most of the configurations utilizing angled backer beams 170, the first cross-backer beams 130 perform similarly in on edge and with weight tests.

[00191] In conclusion, configurations utilizing angled backer beams 170 in every bay are most effective at mitigating bow of the grille assembly. Angled backer beams 170 in bays 2 and 7 (one bay in from the ends) is next most effective. The first cross-backer beams 130 utilizing notches with a notch depth of 0.5 inches were next most effective in reducing bow of the grille assembly. Finally, the second cross-backer beams 130 which did not utilize notches were the least effective in resisting bow.

[00192] Example 2

[00193] A series of tests were performed using grille assemblies according to the seventh through ninth embodiments. Cross-backer beams having notch depths of 0.5 inches and 2.0 inches were tested in various configurations. The slats 110 were 0.75 inches thick, 4 inches tall, and 12 feet long. Several groups of slats 110 were selected which had significant twist along the 12 foot length. One set of slats 110, referred to as “bad” had twist measurements between 17/64 inch and 24/64 inch as measured from one end to the other. In other words, if the proximal end is held vertical, a top or bottom edge at the distal end would be offset from the same edge at the proximal end by between 17/64 inch and 24/64 inch.

[00194] A second set of slats 110, referred to as “terrible,” had twist measurements between 21/64 inch and 56/64 inch. The slats 110 from the bad set were arranged with two slats twisted clockwise and two slats twisted counterclockwise when assembled into a grille assembly. The slats 110 from the terrible set were arranged in the same manner. The grille assemblies were assembled in two different configurations. These configurations were analogous to the grille assembly 900, but the notch depth Hll was 0.5 inch in the first configuration labeled “0.5” Notches.” The notch depth Hll was 2.0 inch in the second configuration labeled “2.0” Notches.” Screws were used as the fasteners 192.

[00195] Figs. 81 and 82 illustrate measurements of slat spacing along the 12 foot length of the slats 110. The measurements of slat spacing were taken at the bottom edge 122 of the slats 110, between adjacent slats 110. Measurements were taken between adjacent slats 110 at the proximal and distal ends of the grille assembly. Measurements were also taken between adjacent slats 110 at two foot increments along the length of the grille assembly. As can be seen, the distribution of slat spacing became substantially narrower when using the 2.0 inch notches as compared with the 0.5 inch notches. This was the case for both the bad and the terrible set of slats 110.

[00196] Example 3

[00197] In another test, grille assemblies were assembled in a variety of additional configurations. Various configurations of grille assembly were assembled using another set of “bad” slats 110 having twist between 17/64 inch and 24/64 inch. The slats 110 were once again assembled with two slats 110 twisting in a clockwise direction and two slats 110 twisting in a counterclockwise direction. Once again, screws were used to fasten the slats 110. In the first configuration, the notch depth was 0.5 inches for all cross-backer beams. In a second configuration, the cross-backer beams had a 0.5 inch notch depth except for those at the proximal and distal ends. The proximal and distal ends utilized cross-backer beams with a 2.0 inch notch depth.

[00198] In a third configuration, the cross-backer beams were alternated such that crossbacker beams having a 2.0 inch notch depth were located at 0, 2, 4, 6, 8, 10, and 12 feet. Crossbacker beams having a 0.5 inch notch depth were located at 1, 3, 5, 7, 9, and 11 feet. In a fourth configuration, exclusively cross-backer beams having a 2.0 inch notch depth were utilized. The slat spacing was measured in the same manner as discussed above.

[00199] Fig. 83 shows the results of the various configurations on slat spacing. Measurements were taken between adjacent slats 110 at the bottom edges 122 at the proximal and distal ends as well as at two foot increments. The first configuration had the broadest distribution of slat spacing, followed by the second, third, and fourth configurations. However, the third and fourth configurations yielded substantially identical results, with only a slight improvement in the fourth configuration as compared with the third configuration.

[00200] As can be seen, the aforementioned embodiments may be combined in any desired manner to achieve a wide range of grille assemblies having varying degrees of resistance to bowing and twist of the slats 110. A grille assembly according to the present invention may incorporate any combination of components as required to achieve the desired end result. Furthermore, the length of the slats 110, notch depths, angle, number, and arrangement of the angled backer beams may be varied to achieve the desired end product.

[00201] Example 4

[00202] In another test, second cross-backer beams 750 A were fabricated to evaluate the strength of the beams with varying radii for the corner radius 787. Material for the second cross-backer beams 750A was solid poplar, 2” by 7/8”. Each second cross-backer 750A had three different notches 764 cut into them. The notches were 1.5” high by 0.75” wide. A first notch 764 had no comer radius 787. A second notch 764 had a corner radius 787 of 0.03” (0.762 mm). A third notch 764 had a corner radius 787 of 0.06” (1.524 mm).

[00203] The cross-backer beams 750A were cut so that each notch had a tooth 768 width of 1.5” on one side and 0.75” on the other side. Strength was measured by fixing the 1.5” wide tooth 768 and pulling on the bottom surface 762 of the 0.75” wide tooth 768. The cross-backer beams 750A were pulled until the 0.75” wide tooth 768 broke. Mean strength for each corner radius value is shown below, along with a percent change as compared with a corner radius of zero (i.e. no corner radius). Fig. 84 also shows the test data and the mean strength.

Table 3. Strength Change by Corner Radius

[00204] The tests indicated that, for a zero comer radius 787, the 0.75” wide teeth 768 almost always broke cleanly at the floor surface 765 of the notch 764. However, for the comer radius 787 of 0.030” (0.762 mm) and 0.060” (1.524 mm), the 0.75” wide teeth 768 did not always break at the floor surface 765 or the fracture line was not parallel with the floor surface 765, even if the fracture initiated at the comer radius 787.

[00205] Exemplary Claims

[00206] Exemplary Claim 1 : A surface covering system comprising: a grille assembly comprising: a plurality of slats arranged substantially parallel to one another, each of the slats extending along a slat axis from a first end to a second end and comprising vertically oriented first and second major surfaces, a bottom edge extending between the first and second major surfaces, and a top edge extending between the first and second major surfaces; a plurality of cross-backer beams, each of the cross-backer beams: extending along a cross-beam axis; oriented so that the cross-beam axis extends substantially perpendicular to the slat axes of the slats; and coupled to each of the slats; the cross-backer beams spaced apart from one another along the slat axes of the slats to form a plurality of bays between adjacent ones of the crossbacker beams; and a plurality of primary angled backer beams, each of the primary angled backer beams: extending along a primary angled beam axis from a proximal end to a distal end; positioned within one of the bays and oriented so that the primary angled beam axis extends obliquely to the slat axes of the slats; and coupled to the slats; and the grille assembly configured to be mounted to a support structure.

[00207] Exemplary Claim 2: The surface covering system according to exemplary claim

1 wherein, for each of the primary angled backer beams, the distal end of the primary angled backer beam abuts a first one of the cross-backer beams and the proximal end of the primary angled backer beam abuts a second one of the cross-backer beams.

[00208] Exemplary Claim 3: The surface covering system according to any one of exemplary claims 1 to 2 wherein the primary angled backer beams are oriented so that the primary angled beam axes are substantially parallel to one another.

[00209] Exemplary Claim 4: The surface covering system according to any one of exemplary claims 1 to 3 wherein each of the primary angled backer beams overlies and is fastened to at least two of the slats.

[00210] Exemplary Claim 5 : The surface covering system according to exemplary claim

4 wherein each of the primary angled backer beam overlies all of the slats of the grille assembly and is fastened to the outermost slats of the grille assembly.

[00211] Exemplary Claim 6: The surface covering system according to any one of exemplary claims 1 to 5 wherein the at least three slats are formed of a solid wood, a composite wood, engineered wood, plywood, or combinations thereof.

[00212] Exemplary Claim 7: The surface covering system according to any one of exemplary claims 1 to 6 further comprising: the grille assembly further comprising: a plurality of secondary angled backer beams; and each of the secondary angled backer beams: extending along a secondary angled beam axis from a proximal end to a distal end; positioned within one of the bays in which one of the primary angled backer beams is also located; oriented so that the secondary angled beam axis extends obliquely to the slat axes of the slats and obliquely to the primary angled beam axis of the primary angled backer beam in the same bay; and fastened to the slats.

[00213] Exemplary Claim 8 : The surface covering system according to exemplary claim 7 wherein, for each of the secondary angled backer beams, the distal end of the secondary angled backer beam abuts a first one of the cross-backer beams and the proximal end of the secondary angled backer beam abuts a second one of the cross-backer beams.

[00214] Exemplary Claim 9: The surface covering system according to any one of exemplary claims 7 to 8 wherein, for each bay in which one of each of the first and secondary angled backer beams are positioned, the first and secondary angled backer beams collectively form a V-shaped brace assembly. [00215] Exemplary Claim 10: The surface covering system according to exemplary claim 9 wherein, for each V-shaped brace assembly, an apex of the V-shaped brace assembly points towards a transverse centerline of the grille assembly.

[00216] Exemplary Claim 11: The surface covering system according to any one of exemplary claim 7 to 8 wherein, for each bay in which one of each of the first and secondary angled backer beams are positioned, the first and secondary angled backer beams collectively form an X-shaped brace assembly.

[00217] Exemplary Claim 12: The surface covering system according to any one of exemplary claim 1 to 11 wherein at least some of the bays are free of any angled backer beams. [00218] Exemplary Claim 13: The surface covering system according to any one of exemplary claim 1 to 12 further comprising: wherein N number of the bays are formed sequentially along a length of the grille assembly starting with a 1 ^st bay at a proximal end of the grille assembly and ending with an N ^th bay at a distal end of the grille assembly; wherein N > 5 ; wherein one of the angled backer beams is positioned in each of the 2 ^nd bay and the (N - 1)* bay; and wherein remaining ones of the bays are free of any angled backer beams.

[00219] Exemplary Claim 14: The surface covering system according to any one of exemplary claims 1 to 12 further comprising: wherein N number of the bays are formed sequentially along a length of the grille assembly starting with a 1 ^st bay at a proximal end of the grille assembly and ending with an N ^th bay at a distal end of the grille assembly; wherein N > 4; wherein one of the primary angled backer beams is positioned in each of the 2 ^nd bay and the (N - I ) ^lh bay; and wherein each of the 1 ^st bay and the N ^lh bay are free of any angled backer beams.

[00220] Exemplary Claim 15: The surface covering system according to any one of exemplary claims 1 to 12 further comprising: wherein N number of the bays are formed sequentially along a length of the grille assembly starting with a 1 ^st bay at a proximal end of the grille assembly and ending with an N ^th bay at a distal end of the grille assembly; wherein N > 3; wherein when N is an odd number, the (^ + 0.5 )* bay is free of any angled backer beams; and wherein when N is an even number, the (- )“ bay and the (- +1)“ bay are free of any angled backer beams.

[00221] Exemplary Claim 16: The surface covering system according to any one of exemplary claims 1 to 15 further comprising: a grid assembly configured to be mounted to the support structure; and the grille assembly configured to be mounted to the grid assembly. [00222] Exemplary Claim 17: The surface covering system according to exemplary claim 16 wherein the grille assembly is mounted to the beams of the grid assembly by coupling the cross-backer beams to beams of the grid assembly.

[00223] Exemplary Claim 18: The surface covering system according to any one of exemplary claims 1 to 17 wherein each of the cross-backer beams is fastened to each of the slats via one or more fasteners.

[00224] Exemplary Claim 19: The surface covering system according to any one of exemplary claims 1 to 18 wherein the plurality of cross-backer beams comprise: a plurality of first cross-backer beams having a bottom surface comprising a plurality of notches formed therein, top portions of the slats nesting within the notches; and a plurality of second crossbacker beams having a bottom surface comprising a planar bottom surface in contact with the top edges of the slats.

[00225] Exemplary Claim 20: The surface covering system according to exemplary claim 19 wherein each of the plurality of notches comprises a pair of opposing sidewall surfaces extending from the bottom surface to a floor surface; and wherein at least one of the plurality of notches comprises a radiused comer between the floor surface and at least one of the opposing sidewall surfaces.

[00226] Exemplary Claim 21 : A surface covering system comprising: a grille assembly comprising: at least three slats arranged substantially parallel to one another, each of the at least three slats extending along a slat axis from a first end to a second end and comprising vertically oriented first and second major surfaces, a bottom edge extending between the first and second major surfaces, and a top edge extending between the first and second major surfaces; and a plurality of angled backer beams, each of the angled backer beams: extending along an angled beam axis; oriented so that the angled beam axis extends obliquely to the slat axes of the at least three slats; and coupled to the at least three slats; and the grille assembly configured to be mounted to a support structure.

[00227] Exemplary Claim 22: The surface covering system according to exemplary claim 21 wherein the angled backer beams are oriented so that the angled beam axes are substantially parallel to one another.

[00228] Exemplary Claim 23: The surface covering system according to any one of exemplary claims 21 to 22 further comprising: the grille assembly comprising: a plurality of cross-backer beams, each of the cross-backer beams: extending along a cross-beam axis; oriented so that the cross-beam axis extends substantially perpendicular to the slat axes of the at least three slats; and fastened to each of the at least three slats; and wherein the cross-backer beams are spaced apart from one another along the slat axes of the at least three slats.

[00229] Exemplary Claim 24: The surface covering system according to any one of exemplary claims 21 to 23 further comprising: each of the angled backer beams and the crossbacker beams having a rectangular transverse cross-sectional profile, a height measured between top and bottom major surfaces, and a width measured between first and second side edges, the height being less than the width; and each of the angled backer beams and the crossbacker beams fastened to the at least three slats so that the bottom major surfaces of the angled backer beams and the cross-backer beams are in contact with the top edges of the at least three slats.

[00230] Exemplary Claim 25: The surface covering system according to exemplary claim 24 wherein each of the at least three slats has a rectangular transverse cross-sectional profile, a width measured between the first and second vertically oriented major surfaces, and a height measured between the top and bottom edges, and wherein the height is greater than the width.

[00231] Exemplary Claim 26: A surface covering system comprising: a grille assembly comprising: a plurality of first cross-backer beams, each of the first cross-backer beams extending along a first cross-beam axis and comprising: a first top surface; a first bottom surface; and a plurality of first notches formed in the first bottom surface, each of the first notches having a first depth measured from the first bottom surface to a first floor surface of the first notch; a plurality of second cross-backer beams, each of the second cross-backer beams extending along a second cross-beam axis and comprising: a second top surface; a second bottom surface; and a plurality of second notches formed in the second bottom surface, each of the second notches having a second depth measured from the second bottom surface to a second floor surface of the second notch, the second depth being greater than the first depth; the first and second cross-backer beams arranged in a spaced apart manner, the first and second crossbacker beams oriented so that the first and second cross-beam axes are substantially parallel with one another; a plurality of slats, each of the slats extending along a slat axis from a first end to a second end and comprising vertically oriented first and second major surfaces, a bottom edge extending between the first and second major surfaces, and a top edge extending between the first and second major surfaces; and the slats mounted to the first and second crossbacker beams so that top portions of the slats nest in the first and second notches so that the top edges of slats contact the first and second floor surfaces, the slats arranged substantially parallel to one another; and the grille assembly configured to be mounted to a support structure. [00232] Exemplary Claim 27: The surface covering system according to exemplary claim 26 further comprising: the grille assembly comprising a transverse center plane that is substantially orthogonal to the slat axes; and the first and second cross-backer beams arranged in a symmetric pattern about the transverse center plane.

[00233] Exemplary Claim 28: The surface covering system according to exemplary claim 27 wherein one of the second cross-backer beams is located along the transverse center plane.

[00234] Exemplary Claim 29: The surface covering system according to any one of exemplary claims 26 to 28 wherein one of the second cross-backer beams is located adjacent to the first ends of the slats and another one of the second cross-backer beams is located adjacent to the second ends of the slats.

[00235] Exemplary Claim 30: The surface covering system according to any one of exemplary claims 26 to 29 wherein the first and second cross-backer beams are arranged in an alternating pattern along the length of the slats.

[00236] Exemplary Claim 31: The surface covering system according to any one of exemplary claims 26 to 30 wherein the top surfaces of the second cross-backer beams and the top surfaces of the first cross-backer beams are substantially coplanar.

[00237] Exemplary Claim 32: The surface covering system according to any one of exemplary claims 26 to 31 further comprising: each of the first cross-backer beams has a first height measured from the bottom surface of the first cross-backer beam to the top surface of the first cross-backer beam; each of the second cross-backer beams has a second height measured from the bottom surface of the second cross-backer beam to the top surface of the second cross-backer beam; and the second height being greater than the first height.

[00238] Exemplary Claim 33: The surface covering system according to exemplary claim 32 wherein the grille assembly is configured to be mounted to the support structure by coupling the first cross-backer beams to the support structure.

[00239] Exemplary Claim 34: The surface covering system according to any one of exemplary claims 26 to 33 further comprising: a grid assembly configured to be mounted to the support structure; and the grille assembly configured to be mounted to the grid assembly.

[00240] Exemplary Claim 35: The surface covering system according to exemplary claim 34 wherein the grille assembly is mounted to the beams of the grid assembly by coupling the first cross-backer beams to beams of the grid assembly.

[00241] Exemplary Claim 36: A surface covering system comprising: a grille assembly comprising: a plurality of first cross-backer beams, each of the first cross-backer beams extending along a first cross-beam axis and comprising: a first top surface; a first bottom surface; and a first height measured from the first bottom surface to the first top surface; a plurality of second cross-backer beams, each of the second cross-backer beams extending along a second cross-beam axis and comprising: a second top surface; a second bottom surface; and a second height measured from the second bottom surface to the second top surface, the second height greater than the first height; the first and second cross-backer beams arranged in a spaced apart manner, the first and second cross-backer beams oriented so that the first and second cross-beam axes are substantially parallel with one another; a plurality of slats mounted to the first and second cross-backer beams, each of the slats extending along a slat axis from a first end to a second end and comprising vertically oriented first and second major surfaces, a bottom edge extending between the first and second major surfaces, and a top edge extending between the first and second major surfaces; and the grille assembly configured to be mounted to a support structure.

[00242] Exemplary Claim 37: The surface covering system according to exemplary claim 36 further comprising: a grid assembly comprising beams, the grid assembly configured to be mounted to the support structure; and the grille assembly configured to be mounted to the grid assembly by coupling the first cross-backer beams to the beams of the grid assembly.

[00243] Exemplary Claim 38: The surface covering system according to exemplary claim 37 wherein the first cross-backer beams are configured to be mounted to the beams of the grid assembly via fasteners extending through the first cross-backer beams and into the beams.

[00244] Exemplary Claim 39: The surface covering system according to any one of exemplary claims 36 to 38 wherein the top surfaces of the second cross-backer beams and the top surfaces of the first cross-backer beams are substantially coplanar.

[00245] Exemplary Claim 40: The surface covering system according to any one of exemplary claims 36 to 39 wherein the top edges of the slats are substantially coplanar with one another.

[00246] Exemplary Claim 41: The surface covering system according to any one of exemplary claims 36 to 40 wherein the bottom edges of the slats are substantially coplanar with one another.

[00247] Exemplary Claim 42: The surface covering system according to any one of exemplary claims 36 to 41 wherein each of the second cross-backer beams comprises a plurality of second notches formed in the second bottom surface, each of the second notches having a second depth measured from the second bottom surface to second floor surfaces of the second notches; and the slats mounted to the second cross-backer beams so that top portions of the slats nest in the second notches so that the top edges of slats contact the second floor surfaces. [00248] Exemplary Claim 43: The surface covering system according to exemplary claim 42 wherein each of the slats has a third height measured from the bottom edge to the top edge; and wherein a ratio of the second depth to the third height is equal to or greater than 0.35:1.

[00249] Exemplary Claim 44: The surface covering system according to exemplary claim 43 wherein the ratio of the second depth to the third height is equal to or greater than 0.5:1.

[00250] Exemplary Claim 45: The surface covering system according to any one of exemplary claims 36 to 44 wherein the first and second cross-backer beams are arranged in an alternating pattern along the length of the slats.

[00251] Exemplary Claim 46: The surface covering system according to any one of exemplary claims 26 to 35 and 42 wherein each of the plurality of second notches comprises a pair of opposing sidewall surfaces extending from the second bottom surface to the second floor surface; and wherein at least one of the plurality of second notches comprises a radiused comer between the second floor surface and at least one of the opposing sidewall surfaces.

[00252] Exemplary Claim 47 : A surface covering system comprising: a grille assembly comprising: a plurality of cross-backer beams, each of the cross-backer beams extending along a cross-beam axis and comprising: a top surface; a bottom surface; and a plurality of notches formed in the first bottom surface, each of the notches having a depth measured from the bottom surface to a floor surface of the notch; the cross-backer beams arranged in a spaced apart manner and oriented so that the cross-beam axes are substantially parallel with one another; a plurality of slats, each of the slats extending along a slat axis from a first end to a second end and comprising vertically oriented first and second major surfaces, a bottom edge extending between the first and second major surfaces, a top edge extending between the first and second major surfaces, and height measured from the bottom edge to the top edge; and a ratio of the depth to the height being equal to or greater than 0.35:1; the slats mounted to the cross-backer beams so that top portions of the slats nest in the notches so that the top edges of the slats contact the floor surfaces, the slats arranged substantially parallel to one another; and the grille assembly configured to be mounted to a support structure.

[00253] Exemplary Claim 48: A surface covering system comprising: a grille assembly comprising: a plurality of cross-backer beams, each of the cross-backer beams extending along a cross-beam axis and comprising: a top surface; a bottom surface; and a plurality of notches formed in the bottom surface, each of the notches having a pair of opposing sidewall surfaces extending from the bottom surface to a floor surface; at least one of the plurality of notches comprising a radiused comer between the floor surface and at least one of the opposing sidewall surfaces; the cross-backer beams arranged in a spaced apart manner and oriented so that the cross-beam axes are substantially parallel with one another; a plurality of slats, each of the slats extending along a slat axis from a first end to a second end and comprising vertically oriented first and second major surfaces, a bottom edge extending between the first and second major surfaces, a top edge extending between the first and second major surfaces; and the slats mounted to the cross-backer beams so that top portions of the slats nest in the notches, the slats arranged substantially parallel to one another; and the grille assembly configured to be mounted to a support structure.

[00254] Exemplary Claim 49: The surface covering system according to exemplary claim 48 wherein each of the plurality of notches comprises a radiused corner between the floor surface and each of the opposing sidewall surfaces.

[00255] Exemplary Claim 50: The surface covering system according to any one of exemplary claims 48 to 49 wherein the radiused comer has a non-zero radius less than or equal to 60 mils.

[00256] Exemplary Claim 51: The surface covering system according to any one of exemplary claims 48 to 49 wherein the radiused corner has a radius in a range between 30 to 60 mils.

[00257] Exemplary Claim 52: The surface covering system according to any one of exemplary claims 48 to 49 wherein the radiused corner has a radius of about 30 mils.

[00258] Exemplary Claim 53: The surface covering system according to any one of exemplary claims 48 to 49 wherein the radiused corner has a radius of about 60 mils.

[00259] Exemplary Claim 54: The surface covering system according to any one of exemplary claims 48 to 53 wherein end-most ones of the plurality of notches comprise a radiused corner formed between an outer one of the pair of opposing sidewall surfaces and the floor surface; and wherein at least one middle one of the plurality of notches are free of radiused comers.

[00260] While the foregoing description and drawings represent exemplary embodiments of the present disclosure, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. In addition, numerous variations in the methods/processes described herein may be made within the scope of the present disclosure. One skilled in the art will further appreciate that the embodiments may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the disclosure, which are particularly adapted to specific environments and operative requirements without departing from the principles described herein. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive. The appended claims should be construed broadly, to include other variants and embodiments of the disclosure, which may be made by those skilled in the art without departing from the scope and range of equivalents.