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Title:
A SYSTEM FOR SUPPORTING A SUSPENDED CEILING BELOW A MAIN CEILING AND A METHOD OF CONSTRUCTING SAID SYSTEM
Document Type and Number:
WIPO Patent Application WO/2018/033735
Kind Code:
A1
Abstract:
A fixture, for attaching to a wall and for use in a system for supporting a suspended ceiling below a main ceiling, comprises primary retaining parts for retaining respective ends of primary support members of the system and secondary retaining parts for retaining respective ends of secondary support members of the system, the primary retaining parts being spaced apart from each other and the secondary retaining parts being spaced apart from each other.

Inventors:
BACCARINI TONY (GB)
Application Number:
PCT/GB2017/052421
Publication Date:
February 22, 2018
Filing Date:
August 16, 2017
Export Citation:
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Assignee:
UNIQUE CONSTRUCTION SOLUTIONS LTD (GB)
International Classes:
E04B9/30
Foreign References:
US20080229680A12008-09-25
EP2034101A22009-03-11
Attorney, Agent or Firm:
GILL JENNINGS & EVERY LLP (GB)
Download PDF:
Claims:
Claims

1 . A fixture for attaching to a wall and for use in a system for supporting a suspended ceiling below a main ceiling, the fixture comprising primary retaining parts for retaining respective ends of primary support members of the system and secondary retaining parts for retaining respective ends of secondary support members of the system, the primary retaining parts being spaced apart from each other and the secondary retaining parts being spaced apart from each other.

2. A fixture according to claim 1 , wherein each of the primary retaining parts is a slot, groove, recess, hole, indent or orifice.

3. A fixture according to claim 1 or 2, wherein at least one of the primary retaining parts is provided by a removable segment within the fixture.

4. A fixture according to any preceding claim, wherein each of the secondary retaining parts is a slot, groove, recess, hole, indent or orifice. 5. A fixture according to any preceding claim, wherein at least one of the secondary retaining parts is provided by a removable segment within the fixture.

6. A fixture according to any preceding claim, wherein at least one end of the fixture comprises a slot adapted to receive a joining member, such that the at least one end of the fixture can be joined to an end of another similar fixture having a similar slot.

7. A system for supporting a suspended ceiling below a main ceiling, the system comprising:

fixtures each according to any one of claims 1 to 6;

primary support members; and

secondary support members.

8. A system according to claim 7, comprising at least one hanger for attaching at least one of the primary support members to the main ceiling.

9. A ceiling support installation comprising a system according to claim 7 or 8, wherein:

a first one of the fixtures is attached to a first wail and a second one of the fixtures is attached to a second wall which opposes the first wall;

the primary support members extend between the first and second fixtures, the ends of each of the primary support members being retained by the respective primary retaining parts of the first and second fixtures;

a third one of the fixtures is attached to a third wall and a fourth one of the fixtures is attached to a fourth wall which opposes the third wall;

the secondary support members extend between the third and fourth fixtures such as to form a grid with the primary support members, the ends of each of the secondary support members being retained by the respective secondary retaining parts of the third and fourth fixtures; and

the secondary support members are attached to the primary support members.

10. A ceiling support installation according to claim 9 when dependent on claim 8, wherein the at least one hanger attaches the at least one of the primary support members to the main ceiling.

1 1 . A method of constructing a suspended ceiling below a main ceiling, comprising:

providing primary support members, secondary support members, and fixtures for attaching to respective walls, each of the fixtures comprising:

primary retaining parts for retaining respective ends of the primary support members and secondary retaining parts for retaining respective ends of the secondary support members, the primary retaining parts being spaced apart from each other and the secondary retaining parts being spaced apart from each other; attaching a first one of the fixtures to a first wall and attaching a second one of the fixtures to a second wall which opposes the first wail; attaching a third one of the fixtures to a third wall and attaching a fourth one of the fixtures to a fourth wall which opposes the third wall;

coupling ends of the primary support members to the respective primary retaining parts of the first and second fixtures;

coupling ends of the secondary support members to the respective secondary retaining parts of the third and fourth fixtures, such that the primary and secondary support members form a grid;

attaching the secondary support members to the primary support members; and

attaching at least one ceiling board to at least one of the secondary support members.

12. A method according to claim 1 1 , comprising inserting cabling between the main ceiling, and above where the at least one of the ceiling boards will be positioned by the at least one secondary support member, after the first and second fixtures have been attached to the respective first and second walls and before the ends of the primary support members are coupled to the respective primary retaining parts of the first and second fixtures. 13. The method of claim 1 1 or 12, comprising:

attaching at least one hanger to the main ceiling; and

attaching one of the primary support members to the at least one hanger, such that the at least one hanger is Iocated at least 800 mm, preferably at least 1200 mm, along the length of the said one primary member from the respective wall.

Description:
A SYSTEM FOR SUPPORTING A SUSPENDED CEILING BELOW A MAIN CEILING AND A METHOD OF CONSTRUCTING SAID SYSTEM

Field of the Invention The present invention relates to a system for supporting a suspended ceiling below a main ceiling and, more particularly, to a peripheral member or fixture for use in said system and a method of constructing a suspended ceiling below a main ceiling using said system. Background to the Invention

Conventional systems for supporting suspended ceilings present problems for electricians who need to consider how best to install various electrical components, such as cabling, between the main ceiling and the suspended ceiling. The various components of conventional systems, such as the primary support members and the secondary support members which are arranged in a grid to support the ceiling boards, present obstacles and make it difficult and cumbersome for the electrical work to be carried out. There are often clashes between components of the system and the electrical work which require return visits as components of the system need to be moved to accommodate for the electrical work. This increases the cost of labour.

Summary of the Invention

According to an aspect of the invention there is provided a fixture for attaching to a wail and for use in a system for supporting a suspended ceiling below a main ceiling, the fixture comprising primary retaining parts for retaining respective ends of primary support members of the system and secondary retaining parts for retaining respective ends of secondary support members of the system, the primary retaining parts being spaced apart from each other and the secondary retaining parts being spaced apart from each other.

The primary retaining parts are discrete parts or elements which are spaced apart from each other in order to define predetermined locations of primary support members relative to a wall to which a fixture is to be attached. In a similar manner, the secondary retaining parts are discrete parts or elements which are spaced apart from each other in order to define predetermined locations of secondary support members relative to a wail to which a fixture is to be attached. Therefore, once each one of a set of fixtures has been attached to its respective wall, at the initial stage of a ceiling support installation, the possible locations of structural support members can be easily determined (i.e. predicted) even before the structural members are coupled to the fixtures (also referred to herein as peripheral members). This predetermination of the locations of the structural supports advantageously provides that electrical work can be carried out, in the space between the main ceiling and the suspended ceiling, before the entire ceiling system is assembled. It is therefore easier to perform the electrical work and there is a significantly reduced likelihood of the need for return visits to move or alter the positions of the structural members of the system at a later date as clashes between the electrical work and components of the system are much less likely.

Each of the primary retaining parts may be a slot, groove, recess, hole, indent or orifice. At least one of the primary retaining parts may be provided by a removable segment within the fixture. Each of the secondary retaining parts may be a slot, groove, recess, hole, indent or orifice. At least one of the secondary retaining parts may be provided by a removable segment within the fixture. At least one end of the fixture may comprise a slot adapted to receive a joining member, such that the at least one end of the fixture can be joined to an end of another similar fixture having a similar slot.

According to another aspect of the invention there is provided a system for supporting a suspended ceiling below a main ceiling, the system comprising: fixtures each as described herein above; primary support members; and secondary support members. The system may comprise at least one hanger for attaching at least one of the primary support members to the main ceiling. According to another aspect of the invention there is provided a ceiling support installation comprising a system as described herein above, wherein: a first one of the fixtures is attached to a first wall and a second one of the fixtures is attached to a second wall which opposes the first wall; the primary support members extend between the first and second fixtures, the ends of each of the primary support members being retained by the respective primary retaining parts of the first and second fixtures; a third one of the fixtures is attached to a third wall and a fourth one of the fixtures is attached to a fourth wall which opposes the third wall; the secondary support members extend between the third and fourth fixtures such as to form a grid with the primary support members, the ends of each of the secondary support members being retained by the respective secondary retaining parts of the third and fourth fixtures; and the secondary support members are attached to the primary support members. The at least one hanger may attach the at least one of the primary support members to the main ceiling.

According to another aspect of the invention there is provided a method of constructing a suspended ceiling below a main ceiling, comprising: providing primary support members, secondary support members, and fixtures for attaching to respective walls, each of the fixtures comprising: primary retaining parts for retaining respective ends of the primary support members and secondary retaining parts for retaining respective ends of the secondary support members, the primary retaining parts being spaced apart from each other and the secondary retaining parts being spaced apart from each other; attaching a first one of the fixtures to a first wall and attaching a second one of the fixtures to a second wall which opposes the first wall; attaching a third one of the fixtures to a third wail and attaching a fourth one of the fixtures to a fourth wall which opposes the third wall; coupling ends of the primary support members to the respective primary retaining parts of the first and second fixtures; coupling ends of the secondary support members to the respective secondary retaining parts of the third and fourth fixtures, such that the primary and secondary support members form a grid; attaching the secondary support members to the primary support members; and attaching at least one ceiling board to at least one of the secondary support members. The method may comprise inserting cabling between the main ceiling, and above where the at least one of the ceiling boards will be positioned by the at least one secondary support member, after the first and second fixtures have been attached to the respective first and second walls and before the ends of the primary support members are coupled to the respective primary retaining parts of the first and second fixtures.

The method may comprise: attaching at least one hanger to the main ceiling; and attaching one of the primary support members to the at least one hanger, such that the at least one hanger is located at least 800 mm, preferably at least 1000 mm, along the length of the said one primary member from the respective wall Brief Description of Drawings

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 depicts a partially assembled system for supporting a suspended ceiling below a main ceiling according to an embodiment: Figure 2 depicts two peripheral members according to an embodiment, which are joined together using a joining member, for use in a system for supporting a suspended ceiling below a main ceiling;

Figure 3 depicts an alternative embodiment of a peripheral member; and

Figure 4 depicts a flowchart of the steps involved in constructing a system for supporting a suspended ceiling below a main ceiling according to an embodiment.

Detailed Description of Embodiments

Figure 1 depicts a partially assembled system 100 for supporting a suspended ceiling below a main ceiling according to an embodiment. The depicted system 100 comprises elongate peripheral members 102 (also referred to herein as fixtures), a hanger 104, a primary member 106, and secondary members 108. Also shown in Figure 1 are a main ceiling 1 10, walls 1 12 and a ceiling board 1 14. Embodiments of the peripheral members are also shown in Figures 2 and 3.

Each peripheral member 102 according to an embodiment comprises parts 102a, depicted in Figure 1 as orifices, each suitable for retaining an end of a primary member 106. Each peripheral member 102 further comprises parts 102b, depicted in Figure 1 as two slots, each suitable for receiving an end of a secondary member 108. The peripheral members 102 may be constructed from metal materials, for example steel, aluminium, or alloys thereof. Alternatively the peripheral members 102 may be constructed from wood or timber, which can offer improved acoustic properties (e.g. reduced resonance) over metal. The peripheral members 102 are attached to the walls 1 12 and the locations of the parts 102a and the parts 102b define the geometry of the grid created by the assembled primary members 106 and secondary members 108, as shown in Figure 1 . In a fully assembled system 100, peripheral members 102 are attached to the walls 1 12 of a room within which the suspended ceiling 1 14 is to be erected, so as to form a perimeter. A grid of primary members 106 and secondary members 108 is assembled based on the locations of the parts 102a the parts 102b, the primary 106 and secondary 108 members thereby providing the supporting structure for the ceiling board 1 14.

Once the peripheral members 102 are attached to the walls 1 12, it is possible to determine the possible locations of the structural members of the system 100, such as primary members 106 and secondary members 108, before the system 100 is fully assembled. Thus, as has already been mentioned herein above, electrical work in the space between the main ceiling and the suspended ceiling can be carried out before the entire system is assembled. The hanger 104 depicted in Figure 1 is attached to the main ceiling 1 10 at one end and to the primary member 106 at its other end. In conventional systems for supporting a suspended ceiling, hangers must be placed close to the ends of the primary members and at regular intervals along the length of each primary member as the ends of each primary member are not attached or retained in any way to the walls. According to standard practice for constructing known suspended ceilings a first hanger is always positioned 450mm from the wall. The spacing between further hangers is 1200mm. For example, when installing conventional MF (metal frame) ceiling components, such as "MF5" plaster board ceiling sections and "MF6a" plaster board ceiling perimeter trims, the secondary bars merely screws the metals together (e.g. using "tek screws") and it is therefore required to have a hanger position 450 mm from the wall to provide stability. Conversely, the system 100 according to embodiments provides peripheral members 102 for fixing to the wails, with parts 102a for retaining ends of each of the primary members 106 and providing support for the ends of each of the primary members 106 such that some of the load of the primary members 106 is borne by the peripheral members 102. As such, the maximum possible distance D between the end of the primary member 106 retained in the part 102a of the peripheral member 102 and the closest hanger 104 is greater than the corresponding maximum possible distance in conventional systems for supporting a suspended ceiling due to the support in bearing the load of the primary member 106 provided by the part 102a of the peripheral member 102. There is therefore no need for a first hanger positioned at 450mm from the wail and the first hanger may instead be positioned at a standard 1200mm from the wail.

Advantageously, this means that less hangers need to be used in the system 100 than in conventional systems as the hanger closest to the wail can be located at a larger distance D from the wall than in conventional systems.

The primary member 106 depicted in Figure 1 is retained at one end by the part 102a of the peripheral member 102 and it is also attached to the hanger 104. In a fully constructed system 100 where the peripheral members 102 form a perimeter, the primary member 106 is retained at both ends by parts 102a of opposing peripheral members 102. The parts 102a facilitate alignment of the primary members 106, thereby enabling the position of the primary member 106 to be known once the peripheral members 102 have been attached to the wails 1 12 and before the primary members 106 and secondary members 108 have been installed.

If the distance between the two walls between which the primary member 106 is to be installed is sufficiently short, the support provided by the parts 102a of the opposing peripheral members 102 in retaining the primary member 106 at each end may be sufficient such that no hangers 104 are required.

The secondary members 108 depicted in Figure 1 are each retained at one end by the parts 102b, shown as slots in Figure 1 , of the peripheral member 102 and are also attached to the primary member 106. The ceiling board 1 14 is attached to the underside of the secondary members 108, as shown in Figure 1 in the same manner as for known constructions of suspended ceilings. In a fully constructed system 100 where the peripheral members 102 form a perimeter, the secondary members 108 would be retained at both ends by parts 102b of opposing peripheral members 102. The parts 102b suitable for retaining an end of a secondary member 108 facilitate alignment of the secondary members 108, thereby enabling the position of the secondary members 108 to be known once the peripheral members 102 have been attached to the wails 1 12 and before the primary members 106 and secondary members 108 have been installed. The secondary members 108 may be further fixed to the peripheral members 102, for example, by using screws or an adhesive. Figure 2 depicts two peripheral members 102 for use in the system 100 which are joined together using a joining member 202. Each peripheral member 102 has a slot 204 adapted to receive an end of the joining member 202. The joining member 202 is shaped such that when the two slots 204 of the peripheral members 102 are aligned so as to form an orifice, the joining member 202 may be press-fitted into the orifice defined by the two slots 204 thereby joining the two peripheral members 102 together via a friction fit, as shown in Figure 2.

Figure 3 depicts an alternative embodiment of a peripheral member 302, Two such peripheral members 302 are depicted joined together using a joining member 202 in the same manner described above in relation to the peripheral members 102 depicted in Figure 2.

Additionally, each peripheral member 302 comprises slots 304 adapted to receive a segment 308. The segment 306 can be press-fitted into the slot 304 and held in place via a friction fit. Each segment 308 comprises a part 102a suitable for retaining an end of a primary member 106, depicted as an orifice in Figure 3, Advantageously, the segments 306 can be swapped with alternative segments, for example, where a different type of part 102a suitable for retaining an end of a primary member 106 is required, such as a slot or a recess. Additionally, the segments 306 can be slid over the end of primary members 108 before being press-fitted into the slots 304 making assembly of the system 100 easier. Figure 4 depicts a flowchart of the steps involved in constructing the system 100.

At step 401 , peripheral members 102 are attached to the walls 1 12 of a room within which a suspended ceiling is to be erected, so as to form a perimeter. At step 402, optionally, any required electrical work is carried out as the positions of the remaining members of the system 100 are now known for the reasons described above.

At step 403, optionally, hangers 104 are attached to the main ceiling 1 10.

At step 404, the ends of the primary support members 106 are coupled to respective parts 102a of the peripheral members 102. Where peripheral members 302 are of the type comprising segments 306, the segments may first be slid over ends of the primary support members 106. The ends of primary support members 106 may then be positioned over corresponding slots 304 in the peripheral members 302 and the segments 306 may then be press-fitted into the slots, thereby holding the primary support members 106 in place relative to the peripheral members 302,

At step 405, optionally, the primary support members 106 are attached to their respective hangers 104.

At step 406, ends of the secondary support members 108 are coupled to respective parts 102b of the peripheral members 102.

At step 407, the secondary support members 108 are attached to the primary support members 106.

At step 408, the ceiling board or boards 1 14 are attached to the secondary support members 108. The following are preferred aspects according to the present disclosure.

Clause 1 . A peripheral member for attaching to a wall and for use in a system for supporting a suspended ceiling below a main ceiling, the system comprising a primary support member and a secondary support member for attaching to the primary support member and for attaching to a ceiling board, the peripheral member comprising a part for retaining an end of the primary support member at a predetermined location relative to the wail.

Clause 2. The peripheral member of clause 1 , further comprising a plurality of parts each for retaining an end of each of a plurality of primary support members at predetermined locations relative to the wail. Clause 3. The peripheral member of clause 1 or 2, wherein the peripheral member further comprises a further part for retaining an end of the secondary support member at a predetermined location along the wall, Clause 4. The peripheral member of any of clauses 1 to 3, wherein each part of the peripheral member is a slot, groove, recess, hole, indent or orifice.

Clause 5. The peripheral member of any of clauses 1 to 4, wherein the peripheral member further comprises a slot at one or more ends adapted to receive a joining member, such that the end of one peripheral member can be joined to another.

Clause 6. The peripheral member of any of clauses 1 to 5, wherein one or more of the parts in the peripheral member for retaining an end of the primary support member are provided by a removable segment within the peripheral member.

Clause 7. A system for supporting a suspended ceiling below a main ceiling, the system comprising:

a primary support member;

a secondary support member for attaching to the primary support member and for attaching to a ceiling board; and

a peripheral member for attaching to a wall,

wherein the peripheral member comprises a part for retaining an end of the primary support member at a predetermined location relative to the wall.

Clause 8. The system of clause 7, wherein the peripheral member comprises a plurality of parts each for retaining an end of each of a plurality of primary support members at predetermined locations relative to the wall.

Clause 9. The system of clause 7 or 8, wherein the peripheral member further comprises a one or more further parts for retaining an end of the secondary support member at a predetermined location along the wall. Clause 10. The system of any of clauses 7 to 9, wherein the peripheral member is a first peripheral member and the system further comprises a second peripheral member for attaching to a further wall, the second peripheral member further comprising a part for retaining an end of the secondary support member at a predetermined location along the further wall.

Clause 1 1 . The system of any of clauses 7 to 10, wherein each part of each peripheral member is a slot, groove, recess, hole, indent or orifice. Clause 12. The system of any of clauses 7 to 1 1 , further comprising one or more hangers for attaching the primary support member to the main ceiling.

Clause 13. The system of any of clauses 7 to 12, wherein each peripheral member further comprises a slot at one or more ends adapted to receive a joining member, such that the end of one peripheral member can be joined to another.

Clause 14. The system of any of clauses 7 to 13, wherein one or more of the parts in each peripheral member for retaining an end of the primary support member are provided by a removable segment within the peripheral member.

Clause 15. A method of constructing a suspended ceiling below a main ceiling comprising the steps of:

attaching a peripheral member to a wall;

retaining an end of one of one or more primary support members by a part of the peripheral member;

attaching a secondary support member to said one of the primary support members; and

attaching a ceiling board to the secondary support member.

Clause 16. The method of clause 15, further comprising the step of inserting cabling between the main ceiling, and above where the ceiling board will be positioned by the secondary support member, after the peripheral member is attached to the wall and before the end of one or more primary support members is coupled to the part of the peripheral member.

Clause 17. The method of either of clauses 15 and 16, further comprising the steps of:

attaching a further peripheral member to a further wall; and

coupling an end of the secondary support member to a part of the second peripheral member. Clause 18. The method of any of clauses 15 to 17, further comprising the steps of:

attaching one or more hangers to a the main ceiling: and

attaching one of one or more primary support members to each hanger; wherein no hangers are located less than 800mm along the length of a primary member to a wall, and preferably no hangers are located less than 1000mm along the length of a primary member to a wall.

The flowcharts and description thereof herein should not be understood to prescribe a fixed order of performing the method steps described therein. Rather, the method steps may be performed in any order that is practicable. Although the present invention has been described in connection with specific exemplary embodiments, it should be understood that various changes, substitutions, and alterations apparent to those skilled in the art can be made to the disclosed embodiments without departing from the spirit and scope of the invention as set forth in the appended claims.