Suspended ceiling system

2,894,291

S. E. SORENSON

SUSPENDED CEILING SYSTEM

July 14, 1959

Filed July 31, 1956

Sheets-Sheet 1

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2,894,291

S. E. SORENSON

SUSPENDED CEILING SYSTEM

July 14, 1959

Filed July 31, 1956

Sheets-Sheet 2

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2,894,291

Patented July 14, 1959

United States Patent Office

2,894,291 _e

SUSPENDED CEILING SYSTEMStanley E. Sorenson, Seattle, Wash.

Application July 31, 1956, Serial No. 601,262 23 Claims. (Cl. 20—4) ¹⁰

The present invention relates to suspended ceiling sys- 15 terns in which the expanded ceiling is made up of multiple panels such as acoustical tiles and the suspension means is completely hidden from view from below. This application is a continuation-in-part of my copending application. Ser. No. 464,431, filed October 25,. 1954. 20

The present architectural trend is toward overhead application of Utility lines in the space above a suspended ceiling. Access to power or telephone wires, plumbing, etc., in this space is obviously required on occasion. Also, it is commonly desired to shift the ceiling lights to 25 better meet the requirements of new tenants. Thus, the advantages attendant upon providing individual removal of the ceiling tile without damaging them are considerable.

In the past the only systems which have permitted 30 ready individual removal and replacement Of suspended ceiling tile or panels have had a part of the suspension system exposed to view from below, the best known of these prior systems being characterized' in that'the edges of the tile rest on exposed flanges provided by· grid mem- 35 bers having a generally: inverted T-sectiOn. The exposure of these flanges or, in fact, the exposure of any part other than the face of the tile itself is normally considered to be highly objectionable from an ornamental standpoint. Having the foregoing in mind it is a princi- 40 pal object of the invention to provide a practical ceiling suspension system which corrects this obvious' defect in the systems commercially common today without unduly Complicating the- supporting grid and without necessitating the use of special tools. 45

Other more particular objects and advantages will, together with¹ this general object; appear and be understood in the course of the following description and claims, the invention consisting in the novel construction and in the adaptation and combination of parts hereinafter de- 50 scribed- and claimed.

In the accompanying drawings:

Fig. 1 is a top perspective view, partly in vertical section, illustrating my system in operation and with one tile partially removed. 55

Fig. 2 is an enlarged fragmentary vertical sectional view taken as: indicated by line 2—2 Of Fig. 1 and still in top perspective.

Fig. 3 is an enlarged fragmentary- vertical sectional view taken as indicated by line 3—3 of Fig, 1. 60

Fig. 4 is a fragmentary top; perspective view of one of the end hangers.

Fig; 5 is a view taken as Fig. 3 and illustrating a modified hanger and runner.

Fig. 6 is a top perspective view, partly in vertical sec- 65 tion¹ illustrating an alternative system for longer tiles in operation and with one tile partially removed.

Fig. 7 is an enlarged fragmentary vertical sectional view taken generally as indicated by ; line Ί—7 of Fig. 6 and still in top perspective. 70

Fig. 8 is an enlarged fragmentary vertical· sectional view taken along; one of the side hangers in the ceiling installation and with, the runner in transverse vertical section.

Fig. 9 is a transverse vertical sectional view through a side joint taken as indicated by line 9—9 of Fig. 8i

Fig. 10 is a fragmentary top perspective view of one of the side hangers.

Referring to the' drawings it is seen that I have illustrated my invention as applied to the suspension of acoustical panels or tiles 9 each of which is provided in at least two opposite edges thereof with a groove or kerf 10. This kerf separates a top lip 11 from a bottom lip' 12 and it will be noted that the tile' has been backcut such that the top lip 11 has somewhat less projection than the bottom: lip 12. Accordingly, when the juncture or joint of two abutting tiles is viewed in vertical cross-section, the opposed kerfs 10 and resulting horizontal gap between the shorter top lips 11 give a cutout of inverted T-shape for receiving suspension apparatus.

Before detailing this apparatus, it will be noted that my suspension system may utilize conventional channel headers 13, commonly known as lather’s channel, which are regularly spaced in parallel relation across the ceiling space and are suspended from the overhead structure as by hanger wires 14. Clamped to and beneath these headers by wire clips 15 are runners 16 of a general channel configuration. The clips 15 are formed of single strands of wire and are of general U-shapc for straddling a header 13. At its ends each clip has foot prolongations 17 bent back at an acute angle to the plane of the clip proper. As best shown in Fig. 3, these feet 17 are adapted to grip a generally V-shaped upper step 18 formed in runner 16: arid press the edges of the step up against the underside of a header 13.

Continuing to further details of the runner 16, it is •seen that each is of a general- channel shape having a stepped upper flange formed by upper step 18 and a flat lower step 19, a lower flange 20. and an upright web or center section 21 extending between the lower step 19 and the lower flange 20. The latter is designed to fit into the kerf TO along the back edge of a tile arid engage the underside of the respective top lip 11 to support the back end of the tile. For a purpose which will be hereinafter brought out in course of describing the procedural steps incident to applying the tile to and removing the tile from their ceiling positions, the vertical width of the kerf TO into which the lower flange 20 is received is intentionally greater than, the thickness (gauge) of the flange. To support the opposite or front end of the tiles there are provided end hangers 22 of a generally Z-shape cross-sectionally speaking. Each of these hangers has a bottom horizontal flange 23 complementing the lower flange 20 of the runners, a central standing flange 24, and a top horizontal flange 25 directed Oppositely to its bottom flange 23 for seating in the lower step 19 of the runners.

The bottom flange 23 of the hangers is downwardly dished- at regular intervals as at 26 to increase the effective vertical thickness of the flange to that of the kerf 10 into which it is to fit. In this manner the hanger can have a relatively snug fit in the tile so that the hanger will not rock relative to the tile arid so that the hanger and tile can be handled as a unit during application of the tile. In this regard, if the tile material is quite; soft, it may be desirable to have the effective thickness of the bottom flange 23 of the hanger slightly greater than the¹ thickness of the kerf to assure a snug fit of the hanger with the tile. The distance between the under face of the top hanger flange 25 and the upper face of the bottom hanger flange 23 is made equal to the distance between the upper faces of the lower runner step and the bottom runner flange. This assures that the upper facesofthe bottom; runneratid hanger flanges20,

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23, respectively, will be at the same level when the top hanger flange 25 rests on the lower step 19. In this latter regard, the steps 18,19 should have a vertical spacing exceeding the thickness of the top hanger flange 25 so that the latter is free to move lengthwise along the 5 lower step 19 and the supporting runner 16 and beneath the channel headers 13 to which the runner is clipped. The central flange 24 of the hangers may be dimpled as at 27 in the direction of -the upper flange 25 to aid in a proper spacing of the central flanges of the hangers and 10 runners. Related to this spacing is the fact that for best stability it is desirable to have the central hanger flange 24 bear against the free end of the top lip 11 of the tile into which the hanger is fitted.

To erect my suspension system the headers 13 are first 15 suspended as by the wire hangers 14 in parallel level relation at intervals normally from two to four tile widths. The runners 16 are then secured by the clips 15 to the leaders in crosswise relation thereto and separated the width of one tile from each other. With the headers and ²⁰runners thus fixed in position, the next step is the actual installation of the tiles 9. It is normally the easiest procedure to insert the hangers 22 in the tiles first before raising them to the ceiling. To install a tile and hanger assembly it is first tilted at an angle with the hanger ²⁵uppermost so as to clear the runners, and the assembly is then raised through the opening between two runners until the kerf at the lower edge of the tilted tile is on the same level as the bottom flanges 20 of the runners. For ease of description consider the front face of ³⁰a runner as being the face of the central flange 21 from which the flange 20 projects and the back face as being the other face of the central flanges, and let the hanger end of the tile be termed the front end thereof. Also, let the runner which lies proximal to the elevated front end of the tilted tile now under discussion be termed the front runner, and the runner which lies proximal to the lower back end of the tile be termed the back runner. With the tilted tile elevated with its hanger as aforesaid, the applicator slips the kerf 10 of the tile’s ⁴⁰back edge onto the bottom flange 20 of the back runner as shown in Fig. 2. Then he allows the front end of the tile with its hanger to drop into place, the central flange 24 of the hanger sliding downwardly relative to the back face of the front runner until the hanger’s -top flange. 25 comes to rest upon the lower step 19 of the front ⁴ runner. In the course of this downward movement of the hanger-carrying front end of the tile, it will be apparent that the tile will have performed a swinging action with the fulcrum of the pivot being the lower edge of the top lip 11 at the back end of the tile. This fulcrum gradually moves rearwardly along the upper face of the lower flange 20 of the back runner as the tile pivots to -a level position. The significance of having the vertical width of the kerf 10 greater than the thickness of the ₅₅bottom runner flange 20 which is received therein will now be apparent, the greater width permitting the tile to partake of such pivotal action. The tile should then be adjusted horizontally so that the back edge of the bottom lip 12 at the back end of the tile will project rear- θθ wardly slightly beyond the back face of the back runner. This slight projection is shown in Fig. 3. At the same time the backcut of the overlying upper lip 11 must be sufficient to provide enough gap between the lip and the front face of the related back runner to permit the tile 65 to be tilted at its front end should it be later desired to remove the tile by reversing the application procedure.

Referring to Fig. 1 it can be seen that any tile which lies in part beneath a header 13 must -be first placed in position alongside of the header and then be slid side- 70 wise with its hanger -along the lower step 19 of the front runner and with the top lip 11 of its back end along the bottom flange 20 of the back runner to bring the tile beneath the header 13.

Thus it is seen that if access is required to the space 75 above one of the tiles 9, the tile can be readily removed by reversing the installation procedure, and namely by pushing up the front or hanger-carrying end of the tile to elevate the related hanger 22 free of its runner 16 and then shifting the tile forwardly while in its tilted position so as to free the back edge of the tile from the bottom flange 20 of the other supporting runner. If the tile to be removed lies partially beneath one of the headers 13 it is necessary to first remove one of the tiles against which its side edges abut, shift -the tile sidewise from beneath the header, and then remove it as just described.

In Fig. 5 I have illustrated a modified runner 16a and end hanger 22a in operative position. Like the runners 16, -the runner 16α is generally channel shaped having a bottom flange 120 fitting loosely in the kerf 10 at the back end of a tile, an upstanding central section 121, and a stepped top flange. At its outer or front side the latter has an upper step 118 which is the same as the step 18 and is gripped by the feet of a clip 15 to be held thereby against a header 13. Accordingly, it will be seen that the only difference between runners 16α and 16 resides in the bottom step 119 of the top flange, and namely in the fact -that this step slopes downwardly from the top of the central section 121 toward the upper step 118 instead of being horizontal.

Hanger 22α is generally Z-shaped and at its upper end has a downwardly sloping flange or locking lip 125 complementing the sloped lower step 119 of the runner 16a. Continuing from this upper flange the hanger 22α has a section 239 which extends downwardly, then slopes backwardly away from the upper flange 125, and then continues downwardly to intersect a lower flange 123 corresponding to the lower flange 23 of hanger 22. This lower flange 123 is generally V-shaped with the vertex of the V being lowermost and offset toward the free back edge of the flange. The depth of the V corresponds to the depth of the dished portions 26 in the lower hanger flange 23, the purpose of the V being to fill the kerf 10 into which the hanger is inserted.

The manner of installation of the modified runner 16α and end hanger 22α is the same as that aforedescribed for runner 16 and hanger 22, and it will be apparent that other changes in shape can be made in the parts of the system without departing from the basic teachings of the invention.

Some accoustical tiles are produced elongated such as a 12 x 24 inch size. Many makes of these tiles will unduly sag if only supported at their ends, but will support their own weight satisfactorily across their width. Such a tile has been designated 9a in Fig. 6 and is illustrated with a modified suspension system which will now be described. This modified system incorporates the same runners 16, clips 15, and headers 13, the change, being the use of a pair of side hangers instead of an end hanger 22. Such a pair consists of complementing right and left hand members designated 222R and 222L, respectively. At their front ends these members have -top flanges 225 for seating on the lower step 19 of a runner 16 in the same manner as flanges 25 of the end hangers 22. Extending downwardly from these top flanges 225 are central sections 224 corresponding to end hanger sections 24, and extending rearwardly from the latter are bottom flanges 223 which correspond functionally to end hanger flanges 23 in that they are fitted into the tile. For this purpose tile 9α has a kerf 210 extending therearound forming continuous top and bottom lips 211, 212, the former being backcut in the same manner as top lip 11 of tile 9. For clarity the long edges of tile 9a will be referred to as the sides and the short edges as the ends. Examining Figs. 6-9 it is seen that bottom flange 223 has -a width no greater than -the depth of kerf 210 and a length slightly less than the length of tile 9a. Furthermore, flange 223 desirably is downwardly dished at intervals to form cups 226 whose function

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is to fill?the kerf in the same manner! as the dished portions 26 of the end hangers 22. To longitudinally strengthen the side hangers the right and left hand sides of hangers 222R and 222L, respectively are provided with upstanding reinforcing flanges 250 which are joined to the: respective side edges of the hangers’ bottom flanges 223. Thus it is seen that these side hangers can be formed from a single, sheet of material.

In preparing for the installation of tiles 9a the runners 16 are spaced apart the length of the tiles and clipped in place to the headers as before. A pair of side hangers is. then inserted into the kerfs 210 along the side edges of the tile 9a to be applied and with the central standing sections 224 of the hangers resting against the front edge Of ithe top lip 211 at the front end of the tile. The latter is then tilted with its front end upward and raised between. the front and back runners by which it is to be supported. Then the back edge of the tile is eased toward the bottom flange 20 of the back runner to bring the rear end portions of the side hangers’ bottom flanges 223 to rest on flange 20. The forward end of the tile is then lowered to bring the side hanger flanges 225 to rest on the lower step 19 of the front runner. During this lowering action the rear ends of the side hangers act as a pivot and at.the same time work further onto the bottom flange 20 of the back runner to give longitudinal support to the tile. In this regard the vertical thickness of the kerf 210 must be sufficiently greater than the combined thickness of runner flange 20 and side hanger flange 223- to permit the pivotal action of the tile. The tiles·. 9a and their side hangers can be shifted - sideways along the runners the same as tiles 9 and their end hangers to bring them beneath a header 13. As in the case of the end hangers, it can be readily understood that a tile equipped with side hangers is removed by reversal of its installation procedure.

Referring to Fig. 9 it is seen that the reinforcing flanges 250 of the side hangers are desirably ribbed outwardly in the opposite direction from the respective bottom flanges 223 so that there will be a line sealing contact at the joint between adjacent hangers. This sealing contact can be aided by slightly canting the top hanger flanges 225 so that the top flanges of each pair of side hangers tend to slope downwardly toward one another.

The advantages of the invention, it is thought, will have been clearly understood from the foregoing detailed· description of the illustrated preferred embodiments. Minor changes will suggest themselves and may be resorted to without departing from the spirit of the invention, wherefore it is my intention that no limitations be implied and that the hereto annexed claims be given a scope fully commensurate with the broadest interpretation to which the employed language admits.