IES58802B2 - Improvements in or relating to suspended ceilings and wall panels - Google Patents

Description

In the construction of suspended ceilings, wooden batons are screwed to a ceiling grid which comprises a system of T-bars interconnected by means of interlocking noggins, the T-bars having slits for receipt of the noggin of another T-bar. Subsequently the ceiling panels are then stapled to the batons. A panel, be it a ceiling panel or a wall panel, consists of a tongue side and a groove side, the groove side having a flange through which the staple is punched thus securing the panel to the baton. Having secured a panel to the baton in this manner, the tongue side of a second panel is then inserted into the groove side of a first panel and the second panel is then stapled to a baton and so on until the ceiling or wall, as the case may be, has been constructed.

This prior art system has several disadvantages, one of which is that in constructing a ceiling, the system is very costly because of the amount of material required and also because the operation itself is time consuming and laborious. A further disadvantage is that since the staples are punched only through the flange of the panel, this means of attachment is not secure in certain circumstances. Furthermore, in the event of one of the panels of a ceiling becoming damaged and falling off, the entire ceiling has to be stripped back as far as the nearest wall and then the broken panel is replaced and the other panels repositioned. Obviously this is quite a time consuming and labour intensive operation.

Furthermore, in constructing a ceiling or wall from panels, various types of trims are used such as starting - 2 trims, intermediate or centre join section trim, external corner, internal corner and pliable joint section trims.

Conventionally, the trim is affixed to a wall or timber baton by means of the flange on the trim being screwed or stapled onto the wall or baton. This type of fixing has the disadvantage that the weight of the entire trim is being carried by the screw or staple through the flange. Thus, this is not a very stable means of holding the trim in place.

The present invention seeks to alleviate the above disadvantages.

In a first aspect, the present invention provides a connector for holding a ceiling or wall panel on a support means, the connector including a nose member adapted to engage the panel, the connector further including a wing member movable between an inoperable position and an in-use position in which the wing member is folded onto the support means so that the panel is held in position on the support means.

Ideally the nose member engages in a groove in a panel.

Conveniently, the connector is slidable along the T-bar.

In a second aspect the present invention provides a novel main runner and baton system, respectively, for use with the above connector.

This main runner has the advantage that it eliminates the need for noggins, slits in T-bars for receiving noggins, timber, screws and staples.

The present invention also provides a latt for use with the connectors of the present invention. Use of the latt and connectors has the advantage that it eliminates the need for glueing.

In a third aspect the present invention provides a trim connector clip for use with starting trims.

The present invention will now be described with particular reference to the following drawings in which are shown various embodiments of this invention.

Figure 1 is a schematic diagram of the prior art system showing the wooden batons screwed to T-bars and then panels screwed to the wooden batons; Figure 2 is a schematic diagram of the prior art trap door system in which the wood or plastic sheet is glued to the panels; Figure 3 is a perspective view of the connector in a first embodiment; Figure 4 is a schematic diagram of the present invention in use, showing a panel in position on a ceiling; Figure 5 is a perspective view of the connector in a second embodiment; Figure 5a is a front elevation of the connector in the second embodiment; Figure 5b is a perspective view of the slide connector in the second embodiment shown attached to a main T-bar; Figure 6 is a perspective view of the connector in a third embodiment; Figure 6a is a perspective view of the connector in the third embodiment screwed onto the main T-bar; Figure 7 is a front elevation of the connector in a fourth embodiment; Figure 7a is a plan view of the connector in the fourth embodiment; Figure 7b is a perspective view of the connector in accordance with the fourth embodiment, shown attached to the main T-bar; Figure 8 is a perspective view of the connector in a fifth embodiment; Figure 9 is a perspective view of the connector in a sixth embodiment; Figure 9a is a perspective view of the connector of the sixth embodiment in use with a circular pipe or tube; Figure 10 is a perspective view of the connector in a seventh embodiment; Figure 11 is a perspective view of the connector in an eighth embodiment; Figure 11a is a perspective view of the connector in accordance with the eighth embodiment in an alternative use holding a sign from the T-bar rather than holding a panel; Figure 11b is a perspective view of the connector in an alternative embodiment holding another type of sign or promotional display; Figure 12 is a perspective view of the connector in a ninth embodiment; Figure 13 is a perspective view of the slide connectors of the seventh, eight and ninth embodiment respectively shown attached to the main T-bar; Figure 14 is a perspective view of the slide connector in a tenth embodiment; Figure 14a is a perspective view of the slide connector in the tenth embodiment in use on the T-bar; Figure 14b is a perspective view of the connector in an eleventh embodiment; and Figure 14c is a front view of the connector in accordance with the eleventh embodiment in use; Figure 15 is a plan view from above showing the main tee bar having a slide connector attached thereto and with the ceiling panels in place; Figure 16 shows schematically the manner in which a damaged panel may be removed and a replacement panel slid into place; Figure 17 is a perspective view of a T-bar with connector of the present invention clipped thereto; Similarly, Figure 18 is a perspective view of the connector clipped onto a C-channel which may be sold with the clip; Figure 19 is a perspective view of a baton system adapted for use with the clip connector; Figure 20 is a front elevation of a latt adapted for use in conjunction with a clip connector system; Figure 21 is a perspective view of a trim connector for use with starting trims in accordance with a third aspect of the present invention; Figure 21a is a perspective view of the trim connector in an alternative embodiment; Figures 22a and 22b are perspective views of the trim connector in use with two alternative types of starting trim; Figure 22 is a perspective view of a trim connector in a further alternative embodiment; Figure 22a is a perspective view of a trim connector in another alternative embodiment; Figure 23 is a perspective view of a trim connector of one embodiment shown in use with an intermediate or centre join section trim; Figure 24 shows a trim connector in an alternative embodiment in use; Figure 25 is a perspective view of a perimeter trim connector; and Figure 25a shows the perimeter trim connector in use, holding a trim in place; Figure 26 is a perspective view of a panel or plank rest connector; Figure 26a is a perspective view of the panel or plank rest connector in use; Figure 27 is a side view of a key for use with ceiling panels; and Figure 27 is a side view of a key for use with ceiling panels; and Figure 27a is a perspective view of the key in use; Figure 28 is a perspective view of a connector in an alternative embodiment which is ideal for use with plaster boards and all dry-linings suspensions systems; Figure 28a is a perspective view of the connector in this alternative embodiment, in use; Figure 28b is a plan view of a series of connectors in this embodiment connected to the dry-lining plaster boards; Figure 29 is a perspective view of a connector in an alternative embodiment ideal for use with clip-on panels and blades using a main primary channel; Figure 29a is a perspective view of this clip in use; Figure 30 is a perspective view of a connector in an alternative embodiment for use with clip-on panels and blades; Figure 30a and 30b are both perspective views of the connector of this embodiment, in use; Figure 31 is a perspective view of a swivel connector for use with clip-on panels and blades; Figure 31a is a perspective view of this connector in use shown connected to the main T-bar; Figures 32 to 32a are perspective views of a swivel connector in an alternative embodiment.

The prior art system is shown in Figure 1. Referring to Figure 1, wooden batons 3 are screwed onto the main T-bar 1 by means of screws 2. A panel 4 may then be attached to the baton either by means of staples or by screws. The disadvantages of this prior art system are described in the introduction.

Referring now to Figure 2, the prior art trap door system is shown in which a wood or plastic sheet is glued to the panels .

It will be noted that although the following description refers to ceiling panels, the connector may be also used for wall panels.

Referring now to Figure 3, the connector of the present invention in a first embodiment will be described. The connector is indicated generally by the reference number 30 and includes wings 31 and nose member 32. In order to construct, for example, a suspended ceiling using connector 30, an operator positions the connector 30 so that the horizontal section 11 of the T-bar 1 is located between the wings 31. 31. The wings 31 are then pressed inwardly and downwardly using the thumb and fingers of one hand so that the connector 30 is held on the T-bar 1. The connector may be slid along the T-bar to any desired position. A number of connectors 30 may be placed on the T-bar 1 in this fashion. In order to hold a panel on the T-bar 1 using the connector 30, the nose member 32 is pushed into the groove side of a panel 4 thereby holding the panel in position. The tongue side of a second panel 4 is then brought into contact with groove side of the first panel 4 and the tongue of the second panel 4 is engaged in the groove of the first panel 4. The nose member 32 is thereby sandwiched between the flange of the first panel and the tongue of the second panel 4. A second connector 30 is then positioned close to the second panel 4 so that the nose member 32 of this second connector 30 engages in the groove of the second panel 4 and holds the panel in position on the T-bar 1. The tongue of a third panel is then engaged in the groove of the second panel 4 and this sequence is continued until an entire ceiling has been constructed.

It should be noted that in order to hold the first panel 4 in position on the T-bar 1 before any other panel is engaged therewith, an operator may make a slit in the tongue side of the panel and the nose member 32 of a connector 30 may be inserted therein so as to hold this first panel in place while a second panel 4 is being brought into engagement therewith.

Referring now to Figures 5a and 5b in which the connector in second embodiment is shown. This connector is indicated generally by the reference numeral 50 and is essentially the same as the connecter 30 except that connector 50 includes a kink 55 in each of the wings 51. The use of the connector 50 is the same as described above except that in this case the connector 50 may be pushed onto the horizontal section 11 of the T-bar 1 in which case the connector 50 will rest on the horizontal section 11 of the T-bar 1 by virtue of the kink 55. The connector 50 may then be pushed or slid along the horizontal section 11 of the T-bar 1 to any desired location and the wings 51 may then be pushed inwardly and downwardly onto the horizontal section 11 so that the connector 50 is held in position of the T-bar 1. A groove side of a panel 4 will then be positioned such that the nose member 52 is inserted into the groove of the panel 4 in the same manner as described above.

We refer now to Figure 6 and 6a in which a connector in accordance with a third embodiment is shown. This connector is indicated generally by the reference numeral 60 and includes a nose member 62, wings 61 and flaps 63 which comprise holes 64. The connector 60 is brought into contact with the horizontal section 11 of the T-bar 1 and the wings 61 are pushed inwardly and downwardly so that the connector 60 is secured on the T-bar 1. The connector 60 may then be moved along the T-bar 1 to any desired location. The flaps 63 are then brought into contact with the vertical section 10 of the T-bar one and the flaps 63 may be screwed to the main T-bar 1 thereby fixedly holding the connector 60 in position on the main T-bar 1.

Referring now to Figure 7, 7a and 7b in which is shown a connector in accordance with a fourth embodiment of the invention. This connector is indicated generally by the reference numeral 70 and includes a nose member 72, wings 71, flaps 73, and overhead portion 74. The connector 70 is brought into contact with the T-bar 1 with the nose member 10 72 aligned with the horizontal section 11 of the T-bar 1.

The connector 70 is positioned at any desired location along the T-bar 1 and the wings 71 are then pushed inwardly onto the horizontal section 11. The flaps 73 abut against the vertical section 10 of the T-bar 1 and the overhead portion 74 overhangs the top of the T-bar so as to provide extra strength.

We refer now to Figure 8 in which is shown a fifth embodiment of the present invention and in which the 20 connector is indicated generally by the reference numeral 80. The connector 80 comprises two wings 81, and two nose members 82. The connector 80 is useful where it is desired to engage each nose member 82 into the grooves of respective panels 4. Alternatively, one may engage one nose member 82 into the groove section of one panel and if one wishes to engage the other nose member 82 into the tongue side of a second panel, one may make a slit using for instance a Stanley knife, into the panel on its tongue side and the nose member 82 may then be inserted into the slit. This may prove convenient in some circumstances.

We refer now to Figure 9 and 9a in which are shown a connector 90 in the sixth embodiment of the present invention. The connector 90 is useful where a circular pipe or tube is provided instead of a T-bar. The connector 90 comprises nose member 92, wings 91 and flaps 93. The flaps 93 include holes through which a screw may be inserted in order to secure the connector 90 onto the tube.

Figures 10, 11 and 12 show respectively the seventh, eighth and ninth embodiments of the present invention which are identified by numerals 100, 110 and 120 respectively and include wings 101, 111 and 121, respectively.

Figure 13 shows the connectors in the seventh, eighth and ninth embodiments respectively located on the T-bar 1. The connector 120 (ninth embodiment of the invention) is ideal for use at butt joints, access panels and trap doors.

Figure 11a shows the connector 110 (eight embodiment) in an alternative use in holding an exit sign on the T-bar and Figure 11b shows the connector in an alternative embodiment for holding signs.

Figures 14 and 14a show the connector in a tenth embodiment. This connector which is indicated generally by the reference numeral 140 and includes wings 141 and nose members 142, is designed particularly for use with panels on which the groove side does not include a flange. This connector 140 is ideal for use in dry lining and plaster board slabbing applications.

Figures 14b and 14c shows the connector in accordance with an eleventh embodiment. The connector is indicated generally by the reference numeral 146. Nose member 147 is arranged at an angle of 45° to the wings 148. This connector 146 is used to achieve a diagonal arrangement (herring bone effect) of panels and produces an aesthetically pleasing effect. The connector 146 has the advantage that the operator does not need to measure the required angle since it is already provided by the connector 146.

The connectors in all of the above embodiments have the advantage that when used in a ceiling or wall system, each connector allows for expansion and contraction of the panels due to temperature fluctuations in the room. This is possible since a limited amount of sliding movement of the connectors along a T-bar or such like, is possible.

The second aspect of the invention is shown in Figures 17, 18, 19 and 20. Referring initially to Figure 17, the connector 30 is connected to the T-bar 1' and the T-bar 1' may be sold with the connector 30 attached thereto. The T-bar 1' has holes along its vertical limb so that the T-bar 1 may be suspended directly from the existing ceiling structure or from brackets mounted on a wall depending on whether one is using the connector 30 and T-bar 1' unit for the construction of a suspended ceiling or a wall. Use of the unit comprising connector 30 and T-bar 1' eliminates the need for noggins on the T-bars.

In Figure 18, a unit comprising a C-channel and connector is shown. For some applications, it may be desirable to use a C-channel rather than a T-bar; a connector in accordance with the present invention may also be used in conjunction with the channel. The connector is used to hold panels in position in the same manner as already described above.

Referring now to Figure 19, a unit 190 comprising a baton 191 with groove 192 is shown with the connector 195 held thereon. This baton 191 may be manufactured from plastics material, wood, or metal such as steel or aluminium, for instance.

Referring now to Figure 20, a latt 200 is shown. The latt 200 may be screwed on to a wall so that the latt is flush with the wall. The connectors of the present invention may then be held on the latt 200. This latt 200 and connector of the present invention may be used instead of brackets o which protrude outwardly from the wall and onto which wall panels are attached.

Referring now to Figure 21 to 25a inclusive, the trim connector in accordance with the third aspect of the invention will described. Referring initially to Figure , a crimped wall and ceiling grid connector for starting trims is shown in a first embodiment and is indicated generally by the reference numeral 210. The trim connector 210 comprises a hook member 211 and a ledge portion 212.

Figure 21a shows the trim connector in an alternative embodiment which is indicated generally by the reference numeral 215. The trim connector 215 comprises a hook member 216 and ledge portion 217.

Referring now to Figure 22a and 22b, the trim connectors 210 and 215, respectively are shown in use, with respective trims 500, 500' and grid 501. In order to secure the trim connector, the respective ledge portions 212, 217 are crimped onto the respective trims 500, 501 and the respective hook members 211, 216 are hooked onto the grid 501 .

Referring now to Figures 22 and 22a, trim connectors in - 15 alternative embodiments are shown. These trim connectors are indicated by numerals 220 and 225 and include respective complimentary hook members 221 and 226.

Referring to Figures 23 and 24, the respective hook members grip a trim (not shown) and hold it in place on the grid or panel walling.

Referring to Figure 25 and 25a, a perimeter trim connector is indicated by the reference numeral 250, and includes hook member 251 and ledge portion 252. This perimeter trim connector 250 is used to connect an angle trim 505 to a staring trim 500. The hook member 251 holds the angle trim and the starting trim together while the ledge portion 252 abuts against the angel trim 505. The ledge portion 252 may be screwed fixedly in position.

The ceiling or wall panel connector or the trim connector, in accordance with any of the above embodiments, can be made from all types of material including stainless steel, light alloys, light metal also P.V.C. plastics and fibre. The connector can be made to suit all types of main grid systems including circular systems. There are major cost savings on expenses involved in construction. The connector is ideal for fixing all trims e.g. intermediate or centre joint section, start and end edging trim, external and internal corner pliable joint section. No batons or screws are needed with the connector therefore there are major cost saving and labour savings. The connector of the present invention can be used to butt joint panels or planks together. The connector is ideal for most types of light fittings. Grid system can be slid through connector to suit recess light fittings. The flange or tongue of a panel is not damaged if something falls from above and comes through ceiling. A panel will slide through the connector in tact. In the prior art systems, the flange tended to tear and could not be refixed therefore a new panel was needed. Repairs to ceilings are faster than old system and can be repaired from overhead where possible by sliding connector into flange of panel or plank along grid system. Old system cannot be repaired from overhead. No drilling or screws are needed for the G.P.S. connector once the grid system is in place. This aspect is extremely convenient for hospitals or business areas where peace and quiet is essential.

The connector of the present invention are particularly useful when it is required to replace a damaged/broken panel. The damaged panel and connector may be removed and replace easily and without need to remove neighbouring panels from the ceiling. The feature is also useful in that is easy to access the area above the ceiling via access panels and/or trap doors.

Referring now to Figures 26 and 26a. The present invention in a fourth aspect will be described. These figures show a panel or plank rest connector indicated generally by the reference numeral 260. The connector 260 comprises a tooth 262, mouth 261 and hook member 263. The connector 260 is used to conveniently allow the positioning of a panel 4 in any desired location. The panel 4 may be supplied in ten foot or twenty foot lengths and usually three or four operators are required for off-loading this length of panel from a truck and positioning it where required across a ceiling or a wall. The connector 260 may be conveniently located on a main T-bar 1 by hooking the hook member 263 over the vertical portion of the T-bar. The length of panel 4 may be conveniently rested on the tooth 262 and then pulled through the mouth 261 and may be located as required. This operation may be carried out by one person since the main weight of the panel 4 may be allowed rest on the tooth 262. This panel or plank rest connector 260 is very convenient for handling lengths of panels or dry-lining.

We refer now to Figures 27 and 27a in which a fifth aspect of the invention is shown. In this aspect the present invention provides a key indicated generally by the reference numeral 270, for use with trap doors and excess panels. The key 270 comprises a substantially L-shaped member 271 and a cap 272, a seal member 273 may be used in conjunction with the key 270. The key 270 may be coloured so as to provide an easy means of identification of the location of a trap door and or excess panel. When the key is in the closed position as shown in Figure 27a, it prevents the panel being pushed upwardly when pressured is applied there to the underneath surface of the panel 4, for instance, when the panels are being washed.

Referring to Figure 28 the connector 280 includes nose members 282, wings 281 and side portions 285. In use the connector is pushed onto a C-channel as shown in Figure 28a with the side portion 285 abutting against the side of the C-channel and the wings 281 pushed over the sides of the channel thereby holding the connector in place. The nose members 282 are each capable of receiving the groove of a panel 4.

Referring now to Figure 29 and 29a, a connector for clip-on panels and blades using the main primary channel is shown in an alternative embodiment. The connector of this alternative embodiment is indicated generally by the reference numeral 290 and includes a wing 291 and flap members 291 ’ . The connector 291 also includes arms 292 for engaging underneath the lip (not shown) of another channel. The connector 290 may be pushed onto a channel such that the side portions 295 abut against the sides of the channel. The connector 290 may be secured on the channel by pushing the wing 291 downwardly onto the inside of the channel and similarly by pushing the flaps 291' onto the channel.

We refer now to Figure 30, 30a and 30b in which a connector for clip-on panels or blades in an alternative embodiment is shown. This connector is indicated generally by the reference numeral 300 and includes wings 302 and arm members 301. This connector 300 is designed for use with channels 350 which include a lip 352 and which are adjoined and which have a in-fill of 351 therebetween.

The channels 350 are connected to the T-bar 1 by means of the connector 300. The arms 301 are inserted underneath the lip 352 of the channel 350 and underneath the in-fill 351 between the channels 350. The wings 302 are pushed onto the horizontal portion of the T-bar 1 thereby securing the channels in place on the T-bar.

We refer now to Figures 31 and 31a in which a swivel connector for use with clip-on panels and blades is shown. This swivel connector is indicated generally by the reference numeral 310 and includes a upper portion 310’* and a lower portion 310'. The upper portion 310'' includes wings 312 and the lower portion 310' includes arm members 311. The upper and lower portions 310'', 310' respectively, are connected by a swivel joint 315. The arms 311 are inserted underneath the lip 352 of a channel 350 while the wings 312 are pushed onto the horizontal portion of the main T-bar thus the upper portion is comprised of the wings 312 is held stationary on the main T-bar while the lower portion including the flaps 311 holding the channel 350 in place, is allowed to swivel through an angle of 360°.

Referring now to Figure 32 and 32a the swivel connector is shown in a alternative embodiment. In this embodiment the 10 swivel connector is in the form of a disc indicated by the reference numeral 320 and includes four wings 322 which are used to secure the disc in place on the main T-bar whilst allowing the channel 350 to swivel.

The multi purpose connectors of the present invention are ideal for fixing most ceiling systems, start and end edging trims e.g. external corners trim, internal corners trim, intermediate or centre joint sections, pliable joint sections and panel or planks to bulk head grib.

They are also ideal for fixing panels or planks together with grid bars to form trapdoors access doors etc. the connectors fixed to T-bars can allow ceiling to be angled 25 up to 180° degrees.

The connectors of the present invention are ideal for fixing a variety of surface mounted accessories to grid system e.g. exit signs, smoke alarms etc.

The connectors are ideal for fixing some surface mounted light fittings while the trim connectors are ideal to butt join panels or planks together. The connectors can be used to hang a variety of signs from suspended grib.

Using the multi-purpose connectors of the present invention, it is possible to fix both the tongue and groove sides of panels and planks to a grid.

Use of the multipurpose connectors of the present invention allows damaged panels or planks to be removed from walls or ceiling by sliding through the connector. The connectors have the advantage that they do not damage flange of panel or of plank if something falls through ceiling.

It is possible to repair damaged or sagging ceiling from above the ceiling, by sliding new connector along T-bar into flanges. The connectors are ideal for fixing around ducting grills - air conditioning and ideal for recess light fittings. T-bar can slide with connector attached through grooves of panels or. planks to accommodate a variety of light fitting sizes, the connectors are ideal for clip on panel and plank systems.

The connectors of the present invention are particularly suited for use with polyvinyl chloride urethane (P.V.C.U) systems.

It will of course be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the invention as defined in the appended claims.

Claims (5)

1. A connector for holding a panel on a support bar having laterally extending flanges, for use in construction of 5 suspended ceilings, walls and partition walls, the connector including a nose member releasably engagable with a panel, and a wing member of flexible material, the wing member being movable between an inoperable position and an in-use position in which the wing member is folded over 1 o onto a flange of the support bar thereby holding a panel in position on the support bar.

2. A connector according to claim 1 wherein when the wing member is in the in-use position, the connector is slidable 15 along the support bar to a desired location in order to allow construction of a suspended ceiling, wall or partition wall, the panel being attached thereto or disengaged therefrom as desired. 20

3. A connector according to claim 1 or claim 2 wherein the flexible material of the wing member is crimpable so as to allow the connector to be crimped securely in position on the support bar. 25

4. A connector for holding a trim on a support bar having laterally extending flanges, for use in construction of suspended ceilings, walls and partition walls, the connector comprising a backing member having a hook member mounted thereon for holding the trim in position, and a 30 grip member for securely gripping the support bar, the grip member being in a plane substantially at right angles to the plane of the hook member.

5. A connector for use in construction of suspended ceilings, walls and/or partition walls using panels, substantially in accordance with any of the embodiments herein described with reference to and as shown in the accompanying drawings .