System for providing a false ceiling able to recover traditional false ceilings supported by reversed T- bars

A variety of types of false ceilings and methods of furnishing the same are known. Modular false ceilings have been a remarkable development in recent years. Among those types of the known state of art the following three types can be mentioned:

- Modular false ceiling consisting of sealed panels for white rooms. This type of false ceiling is manufactured by specialized companies which operate in the chemical, pharmaceutical, and foodstuff fields, however, it is designed and made by craft with di-fferent modalities according to type;

- Modular false ceiling consisting of straight bars (staves) and panels supported thereby with a variety of shapes and materials. This type of false ceiling is usually manufactured by companies producing false ceilings of fibres and/or metals. It is based essentially upon open sections with a large base and a reversed ω shape which are suspended by means of anchor-shaped suspensions and form a grid with ^" a square or rectangular mesh by using suitable accessories belonging to the system. The models of the companies devoted to the quality are also provided with slots to allow the panels to be integrated with reversed T-sections and to provide a greater versatility of use.

- False lacunar. This type of ^' false ceiling has been traditionally made of wood or die cast plaster by craft. Some companies have proposed solutions of false

lacunar made of plasterboard panels by using a variety of metal section bars for plasterboards available on the market.

Millions of square meters of false ceilings are presently installed all over the world having as

^' carrying structure reversed T section bars which fit to one another to form a grid with meshes of several

.sizes. These false ceilings made especially to ^" hide the installations or to protect upper floor against ■ fire are renewed from time to time.

The reason for their wide spread is as follows: a. these false ceilings can be installed easily and quickly also by not specialized workers; b. . such an ease of installation causes the false ■ ceilings to be preferred for large areas also _, due to the fact _. that they are manufactured with high productivity and at a very low cost.

The present patent application aims at providing a method which allows the conventional ^' mesh structures to be used and installed by the mutual coupling of reversed T-sections as carrying structure of a broad variety of shapes and materials. Under such . mode of operation, in case of a new furnishing of false

- ceilings to rooms already provided with a false ceiling, all materials of the old false ceiling of mineral fibres or the like can be recovered and used again integrally in situ. This not only to avoid the problem of disposing the materials of the pre-existing false ceilings but also to reduce the times of dismantling and assembling the materials of the new furnishing. In fact, as the pre-existing mesh structure is not dismantled, not only the cost of

dismantling and differentiate disposing the ^' materials of the old false ceiling but also the . cost of purchasing and assembling the fastening ineans, the new suspension members and the carrying structure are ^• saved. In addition, even if the pre-existing panels are dirty or aesthetically spoiled because of water or sewage percolation due to leakage or dust or soot, they can be used again keeping thermal insulation and soundproofing features unchanged. The components of the present finding that allow such objects to be achieved are:

- The "joint" consisting of an opened box-like member having a ω-section both according to the longitudinal

^• and transversal axis astride of the reversed T- structure to support directly the finishing elements

(panels) of the false ceiling or other intermediate members which in turn support the ornamental and finishing elements of the false ceiling. The joint is above all necessary when the finishing elements of the false ceiling are particularly heavy.

- ^• The "opened small piece" consisting of a box-like parallelepiped element with the upper surface being . notched with a shape able to receive the tabs of the joint so as to couple thereto preferably by rotation or, as an alternative, by removable fitting ^" (snap clip) or by sliding between two guides formed therein. Such small piece can also be produced so that the notches in the upper surface can engage directly with the arms of the "reversed T" in case the finishing .materials to be supported are light enough and do not . require necessarily any use of the joint.

- The. "small piece at- sight" consists of a "opened

small piece" which is covered by a decorative jacket or cap of painted metal sheet or other suitable material to which a decorative element of wood or other suitable material is applied at sight at its lower portion. This small piece can also be produced in one piece so that the notches in the upper surface can couple directly with the arms of the "reversed T" in case the finishing materials to be supported are light enough and do not require necessarily the use of the joint.

- The "sealed panel" is a metal panel shaped such that it is provided at its upper hidden surface with even portions to which elastic seals are applied to guarantee the perfect adherence to the lower surface of the "reversed T" structure upon installing the false ceiling. These panels are fastened to the "joint" by springs of harmonic steel wire.

- The "frame panel" is a box-like panel with a modular size which is a multiple of the pitch of the mesh consisting of reversed T-bars, such frame panel having a "C"-shaped cross section which is bent to the inside

■. and a ω-shaped longitudinal section which is bent to the outside.

The typical elements of the finding have been disclosed hitherto, however, the system consists of further elements which are not part of the finding but are just used to complete the system, i.e. :

- The "reversed T" bars by which the mesh supporting the other elements is formed. - The "bar or stave" which is an essentially straight element with a cross section like to "frame panel" but without bending. This element can be extended by means

of a straight "U"-shaped joint placed inside .the ^' two bars to be joined. • ^■

- The "completion panel" is the final closure panel of the false ceiling of the present system. Description of the joint (Table 1/15)

The joint (fig. 1) is an opened box-like member with ω-shaped cross and longitudinal sections (fig. IA) preferably made" by cold or hot moulding suitable materials . According to an illustrative not limiting embodiment this member can be manufactured by cold moulding a metal sheet: during ^' a first step, the member is moulded with a cross shape (fig. 2) provided with arms with a suitable length ending in arrow points (fig. 2, . detail A) . These ends are provided with notches (fig.

2, detail A, portion Al) and slots (fig. 2, detail A, portion ^' A2) formed to receive further accessories suitable for assembling the broad variety of false

-ceilings. During^ a second step the arrow points are bent ^' all to the same direction (fig. 3) near the slots and then also the cross arms will in turn bent, thus providing the ω-section (fig. IA) . , Description of ^' the accessory "opened small ^, piece" . (Tables 2/15, 3/15 ^' and 4/15) ^{' '}

The accessory "opened small- piece" (fig. 4) is an opened box-like member with "U"-shaped cross and

• longitudinal sections (fig. 4A) preferably made by cold or hot moulding suitable materials. It is subjected to the following machining:

1. During a first step, the metal sheet is. cut according to a cross shape with short arms (fig. 5),

the central portion of which is machined as follows: - a slot with, a complex polygonal shape (fig. 5, detail Ai) able to receive the arrow end points of the joint fitted therein by rotation; - a series of square slots (fig. 5, detail A2) able to

. receive the coupling tabs both of the "covering cap" which is a variation of the "ornamental cover" disclosed in the following paragraph and serves to transform the "opened ¹ small piece" into the "small piece at sight", and the panels which _* are called "frame panels" and connect the small pieces for fastening the same upon assembling the false ceiling. 2. During a second step the arms forming the cross are bent .all to the same direction at the rounded off corners, thus providing the U-shaped section (fig.

4A) .

^■ This accessory can be made of a variety of materials, by several techniques ■ and with different shapes including (Table 3/15) the elongated shape (fig. 4B) or the parallelepiped cross shape (fig. 4C) .

As an alternative to the rotation further mechanical securing methods are provided including only by way of a not limiting example also the removable elastic fitting (by a snap clip as. shown in fig. 4D) or still the slipping between two guides formed in the upper surface ^" of 'the accessory (fig. 4E) . .

A further variation claimed provides that the notches

^' _. formed in _. the ^• upper surface of the accessory during the first machining step disclosed above can couple directly to the arms of the "reversed T" (fig. 4F of Table 4/15) . This is possible by giving the slot a different complex polygonal, shape followed by drawing

and bending the notches such as to receive by rotation (fig. 4E) or by snap coupling (Fig. 4G) the side tabs of the "reversed T" bar.

Thus, one possible variation of the slots made during the first step of machining of the "opened small piece" able to receive the side tabs of the "reversed

T bar .is now disclosed by way of a not. limiting example (fig, 4F, detail A and fig. 4G, detail A) .

^' These slots with bent and/or drawn .portions are alike and disposed symmetrically with respect to the diagonals and the axis of the square upper surface of the accessory so-called "opened small piece" such that

^■ the bent and/o drawn portions are superimposed to the arms of the ^' "reversed T" bar forming the carrying structure following the rotation about- the axis passing through the centre of the accessory or . the thrust from the bottom during the assembling. Description ^' of , the ACCESSORY "SMALL . PIECE AT SIGHT" (Tables 5/15 and 6/15) ^{' '} The accessory "small piece at sight" is a closed box- like parallelepiped member (fig. 6) to be used in all cases wherein upon assembling the false ceiling a node is kept at sight (see for example some types of false, lacunar) . , It is preferably assembled by coupling "opened small piece" disclosed above (fig. 4, Table 2/15) with, the accessory (ornamental ^' cover" (fig. 8, Table 6/15), however-, it can also be made according to a one-body variation which does not use the above-mentioned "opened small piece".

The "ornamental cover" masks the lower opened portion and, in some embodiments, the side portions of the

"opened small piece", thus finishing the latter to provide the "small piece at sight" (fig. 6) . In case the "ornamental cover" conceals ^' also the side portions of the ^' "opened small piece", it is referred to as "cap".

The above-mentioned accessory "ornamental cover" (fig. 8, table 6/15) is a small panel, the lower surface of which may have a number of aesthetical variations laying on a plane such as by way of a not limiting example the drilled surface having square holes as shown in fig. 7A or in bas-relief such as the pyramidal shape drawn in fig. 7B, and can be made by cold moulding painted metal sheet or another suitable material, hot moulding, vacuum thermoforming of plastic sheets, casting of plaster or another suitable material ,or wood milling, etc. according to several machining methods .

In case the "cap" (ornamental cover) is formed by moulding metal sheet, it is subjected to the following machining steps:

1. A first machining step in which the edge of the square metal sheet or the band are subjected to shears (fig. 9, Table 6/15) to form a cross with short ^" arms, tabs to fasten the "cap" to "opened small piece" to ^' transform the same into a "small piece at sight", and end cuts ^' at 45° to determine the bending edge ^' s for the following step and the piercing and/or drawing of the surface which will be at sight;

2. A second machining step to bend the metal sheet in the shape of a parallelepiped opened at its upper side to finish the end piece by the coupling ^' with the "opened small piece" in the following step.

Fig. 9, detail A of Table 6/15 shows the coupling tabs of the covering "cap" of the "opened small piece" for fastening the two components to form the "small piece at sight". ^' If a pre-painted metal sheet is not used for the "cap", the "small piece at sight" is subjected to a further processing: painting.

Bent tabs (detail A) for fastening "cap" to "opened small piece" can be seen in the cross section of fig. 6A.

In false ceilings which need not to leave at sight the side portions of "opened small piece", the "small piece at sight" is . assembled by inserting the "ornamental cover" into the open lower portion of the "opened small piece" (Table 5/15, fig. 6bis) .

An "ornamental cover" made of wood and secured to the "opened small piece" to form the "small piece at sight" is shown in the cross section of fig. 6C. If the "small piece at sight" is made according to the "one-body variation" and the use of the "opened small piece" is avoided, it will have at its upper portion the same coupling members to connect to the joint as the "opened small piece". Of course, also the "small piece at sight" as already . disclosed for the "opened small piece" can be produced according to the variation in which the use of the "joint" can be excluded upon assembling false ceilings made of light enough materials. In this case, the "small piece at sight" has ^' at its upper surface the elements previously disclosed and illustrated to couple to the arms of the "reversed T" bar forming the structure of the false ceiling.

Description of the panel of the sealed false ceilings (Tables 7/15, 8/15, and 9/15) . ■ • Because of its cross sectional shape (fig. 10A) the panel (fig. 10) is perfectly adherent . to "reversed T" bars to form a "sealed" closure between the room with the ^• false ceiling and the remaining room at the extrados of the ceiling.

Figure 1OB shows a cross section of the coupling means between the' reversed T structure' and the sealed panels. As can be seen, the seal is of a suitable elastic ^' material causing the structure to adhere tightly to the panels. .

The panel with a square or rectangular shape can be formed by .cold moulding metal sheet or other suitable material. It consists of an opened box-like element carrying accessories with a triangular shape at the four corners (fig. 11, Table 8/15).

In a • first ^• step the square metal sheet are subjected to an edge trimming in the shape of a cross with short arms and end cuts at 45° (fig. 14, Table 8/15) which determine the bending edges. Shears are also provided at the. four corners to form tabs (fig. 14, detail A) to receive and to secure the accessories with triangular shape (fig. 15C, detail A, Table ^' 9/15) for fastening ^' the springs to the panel.

In- a second . step, three folds for each side are provided: the first fold to one direction and the other two to another direction, thus providing the final profile of the -panel (fig. 1OA, Table 7/15) and in particular the edge of contact of the panel with the reversed T bars (fig. 1OB, Table 7/15) of the carrying structure.

In the third step the triangular accessories provide with springs (fig. 15A, Table 9/15) will be assembled after being drawn near the corners of the panel (fig. 15B, Table 9/15) and blocked after having ^' bent the ^' tabs formed in the upper portion of the _. panel (fig.' 15C, detail A, Table -9/15).

The triangular accessories can' also be formed by cold moulding metal sheets to form a drawn housing or

.ashlar (fig. II, detail- A, Table 8/15) for receiving a' round bar which secures to the panel the compression springs (fig. 12, Table 8/15) made preferably of harmonic wire with a s-uitable section and serving to- provide the traction to ^' the panels and to cause them to adhere to the reversed T bars. These springs are crossed by the round bar (fig. 13, detail A) and inserted into the slot (fig. 11, detail. B) formed in the triangular accessory and the round bar will be blocked under the ashlar of such accessory (fig. 13, Table VIII) . ■ At last (fig. 15D, Table 9/15) a seal of a suitable elastic material for sealing the panel once the same are ^" installed under the "reversed T" structure is. applied to the -upper -edges of the panel. ^{' '} Description of the frame panel (Table 10/15) The "frame panel" (fig. 16) is an opened box-like element made preferably by shaping and moulding metal sheets- of steel, aluminium or other suitable material. ^' This element can also be produced with other materials and by .several cold or hot techniques suitable for their machining.

^■ If the frame panel is formed by moulding metal sheets, it will be subjected to:

• 1. a first machining step wherein the square metal sheet or the band is subjected to shears of the edges (fig. 17)- according to a cross shape with short arms, cuts to form the tabs to secure the "frame panel" to the "small piece at sight" (fig. 17, detail A) and end cuts at 45° to determine the bending limits for the following step;

2. a second machining step wherein the panel is bent to get the shape of a parallelepiped opened to the upper portion with inside folds in the transversal direction (see section 16A) and outside folds in the ■ longitudinal direction (see section 16B) .

Description of the bar or stave

The bar or stave is a "C" bar having a cross section like the frame, panel and made preferably by shaping metal sheets of steel, aluminium or other suitable ^■ material. It is coupled to the joint through any

"opened . small piece" already disclosed according to a variety of embodiments. . The bar can also be made of other materials by hot or cold methods suitable for the machining of such

. ^■ materials . . ^•

Description of the support panel

The "support panel" is the final closure member of the false ceiling and can be made by cold moulding metal sheet, plaster cast in a die, paper ^, board, vacuum thermoformed plastic materials etc.

According to what disclosed and illustrate above several methods of assembling the false ceiling can be carried out by using the elements on which the system is based. ■ ^■

Some ways of assembling a false ceiling are disclosed

thereafter by way of an, indicative, not limiting example.

Method of assembling a false ceiling with straight ' bars and panels with "reversed T" structure (Tables 5 11/15 and 12/15) ^' .

Joint 1 is inserted from. the top (fig. 18) preferably at the cross coupling between reversed T bars 2 (fig.

18) forming the primary and secondary structures (fig.

19) and can receive a further accessory, the so-called 10 "opened small piece" 3 (fig. 20) which is opened at the lower side and is fastened to the joint without screws just by rotation (figs. 21 and 22) or fitted resiliently by removable snap clip or still by sliding into the seats formed therein. It- will remain

15 concealed by the straight bars 4 (fig. 23) which will be inserted by snap coupling (fig. 24) astride thereon. These straight bars ^' can be extended (fig. 25) through a straight joint 5 (fig. 25) which will remain concealed therein and have the function to support

'20 ^" panels 6 (fig. 26) with several even not flat geometries ^' which will be just laid down (fig. 26) thus providing the final aspect (fig. 27) .

Method of assembling a false lacunar (Tables 13/15 and 14/15) ^{• '• ' ■}

25 Joint 1 is inserted from the top (figs 28 and 29) and is ready to receive an ornamental pr not "small piece at sight" 7 (fig. 30) which is fastened to the joint without screws but just by rotation (fig. 31) or sliding into the seats formed therein. Rectangular

30 ^' panels, so-called frame panels 8, are secured to the small < pieces attached under the cross point between reversed T bars 2 forming primary and secondary

structure so that they can slide between the small piece at sight 7 and the reversed ,T bar 2 (fig. 33), thus providing a large square seat (fig. 34) ready to receive plugging panels 9 (fig. 35) . Such panels can further be secured by bending the tabs at the edge of the panel to enter suitable slots formed in the upper

^' portion of the small piece. At last, further panels that can be made of several materials with several shapes are mounted in the remaining empty spaces for finishing purposes (fig. 36) .

Method of assembling the sealed false ceiling (Table

15/15)

Joint 1 is inserted from the top (fig. 37) preferably at the cross point between reversed T bars 2 forming the primary and secondary structure and is ready to receive the coupling springs 10 of panels 11 (fig. 38) made of metal or other suitable material which will be tightly adherent to the flat base of the reversed T bar 2 with their even portion on which a seal 12 is placed owing to the above-mentioned springs (fig. 39) , thus providing a tight closure (figs. 40 and 41) . A number of advantages can be achieved by the use of the system proposed. The most important are: - False ceilings can be installed by using the reversed T ^• bars as carrying structure which are most preferred by installers and other categories of craftsmen of false ceilings by their easiness of assembling and cheap price. - Retailers of finishing building materials can reduce the types of section bars to be stored as they can cover an extended range of types of false ceiling by

only one kind thereof.

- The carrying structure and the structure at" sight can. be assembled in different times, thus deferring the two steps and leaving the installers free to intervene without causing damages to the portions at .sight of the false ceiling.

- By using the present method there are greater possibilities of personalization of the false ceilings with respect to the current offer. ' - The old false ^■ ceilings made of fibres or the like can be recovered even if the panels are dirty or damaged.

- Times and cost of dismantling of- the old false ceiling are saved. -.The total recovery of the materials of the old false ceiling avoids the selection for their disposal.

- In' case of replacement of the pre-existing false ceiling it is not necessary either to purchase and

_. install again the components necessary to the suspension of the false ceiling or to install further carrying members or to purchase, additional insulating materials '.if not needed to increase the thermal or acoustical insulation over those of the pre-existing false ceiling. In any case the recovered panels can be ^■ used again together with the new ones, thus providing a remarkable saving and an ^■ ecological advantage.

- It is possible to renew sealed false ceilings ^' by using the old carrying structures: for example, in case of change of destination of the room with false ceiling from a clothes shop to a butcher's shop, the common old false ceiling of fibre material can still be used by embodying it in the ^' new false ceiling just

by using the joint and the sealed panels. • ^■ ■— Increase in the manufacturers who can undertake the construction of, false ceilings, thus increasing the offer and the variety.- In fact, as the reversed T structure can be easily assembled, any installer can make us of it, thus ^' increasing the offer on the market.

Formal and structural variations can be made to the solutions proposed within the same inventive concept which is defined by the appended claims.