US3903660A

US3903660A - Ceiling construction

Info

Publication number: US3903660A
Application number: US396153A
Authority: US
Inventors: Mark M Akins
Original assignee: Individual
Current assignee: Individual
Priority date: 1973-09-11
Filing date: 1973-09-11
Publication date: 1975-09-09
Anticipated expiration: 1992-09-09

Abstract

An air circulating or distributing ceiling construction incorporating suspended fiber mat filters which, while effective for the entrapment of airborne dust particles and the like, is also capable of effectively passing light, sound and liquid from concealed lights, speakers, and a ceiling mounted fire extinguishing system, the filters also having some sound absorbing qualities as well. Additional sound absorption is provided by locating sound absorbing material behind the filters thus avoiding an impairment of the capabilities of the sound absorbing means by airborne dust and the like. The use of filters in lieu of the conventional concealment methods of glass, plastic, etc., will allow the use of a smaller fan motor, thus a reduction in noise and electricity.

Description

United States Patent Akins 1 1 CEILING CONSTRUCTION [76] Inventor: Mark M. Akins, 7203 Rollingwood Dr., Chevy Chase, Md. 20015 221 Filed: Sept. 11, 1973 21 Appl. No.; 396,153

[52] US. Cl. 52/27; 52/144; 52/220;

55/DIG. 16; 98/40 D [51] Int. Cl. E04F l7/04 [58] Field of Search 52/27, 28, 145, 144, 168,

52/220, 222,221, 173; 98/40 D, 40 DL; 55/524, DIG. l6

[56] References Cited UNITED STATES PATENTS 2,218,453 10/1940 Mickle 1. 55/DlG. 16

2,251,663 8/1941 Darbo 1 4 1 4 98/40 D 2,683,408 7/1954 Brown et a1. 1 98/40 D 2,384,512 4/1959 Wakefield 98/40 D X 3,084,492 4/1963 Dorsak et a]. 55/DIG. 16

3,376,805 4/1968 Deddo et al. 98/40 D X 3,482,505 12/1969 Sawyer ct a]. 98/40 D [4 1 Sept. 9, 1975 3,559,560 2/1971 Trahan 98/40 D Primary Examiner-Price C. Faw, Jr. Attorney, Agent, or FirmDennis0n, Dennison,

Townshend & Meserole [57] ABSTRACT An air circulating or distributing ceiling construction incorporating suspended fiber mat filters which, while effective for the entrapment of airborne dust particles and the like, is also capable of effectively passing light, sound and liquid from concealed lights, speakers, and a ceiling mounted fire extinguishing system, the filters also having some sound absorbing qualities as well Additional sound absorption is provided by locating sound absorbing material behind the filters thus avoid ing an impairment of the capabilities of the sound ab sorbing means by airborne dust and the like. The use of filters in lieu of the conventional concealment methods of glass, plastic, etc., will allow the use of a smaller fan motor, thus a reduction in noise and electricity.

9 Claims, 4 Drawing Figures i fgg 1 i 33 III/A tram "av-WE] W ages/ 1- All? FLOW CEILING CONSTRUCTION The present invention relates to new and useful improvements in ceiling construction and is particularly concerned with construction wherein uniquely devised filters are utilized so as to conceal, protect and maintain at peak operating efficiency various desired ceiling mounted systems including illumination systems, loud speaker systems, fire extinguishing systems and sound absorbing systems.

Basically, a ceiling constructed in accordance with the invention will incorporate an air circulating or distributing duct system normally incorporating both supply and return ducts. in order to reduce air flow generated noises, the ducts will have appropriate acoustical or sound absorbing material associated therewith. In addition, the low friction loss of the filters in comparison to the conventional concealment methods of glass, plastic, etc. will allow the use of a smaller fan and fan motor, and thus will reduce the noise level and electric power. Further, the ceiling will incorporate illuminating means, sound absorbing material to entrap noise generated from the underlying room or area, and, depending on the particular installation, a public address system of multiple speakers and a liquid distributing fire extinguishing system. Underlying all of these components as a concealing and protective means therefor is a system of fiber mats or filters which act so as to entrap airborne dust particles in the return air before they reach the air circulation system and any dust particles in the supply air (clean air) which may have not been entrapped by the ceiling return air ceiling filter or the central filter system (when needed for additional air purity such as a central electronic filter) so as to maintain the concealed systems, components and materials at peak operating efficiency. By the same token, the filters are so constructed as to, in a substantially unimpeded manner, allow the transmission of air, light, sound and, in the event of a fire, liquid. The filters themselves will be constructed of continuous fibers of glass, polyethylene, or polyester bonded by an appropriate thermosetting resin providing a generally selfsustaining or supported mat.

Other objects and advantages of the invention will become apparent from the following description in conjunction with the accompanying drawings wherein:

FIG. I is a cross sectional view through one type of ceiling incorporating the features of the invention;

FIG. 2 is a similar view through a second form of ceiling;

FIG. 3 is a cross sectional detail through one type of filter constructed in accordance with the instant invention; and

FIG. 4 is a cross sectional detail through a second form of filter.

Referring now more specifically to the drawings, it is initially pointed out that while the ceiling construction system of the invention can be adapted to basically any type of ceiling, it is shown herein for simplicity incorporated into a coffered ceiling or one provided with apparatus accommodating bays. In this regard, FIG. I illus trates a ceiling construction wherein laterally spaced parallel support beams support an overlying deck l2 and define a series of bays I4. With this type of construction, the air circulating or distributing duet system, generally designated by reference numeral 16, is appropriately suspended within the bays l4.

In the arrangement of FIG. 2, the deck 18 is integrally formed with depending beam-like ribs 20 arranged in either laterally spaced elongated runs or in a grid pattern defining, in either case, the ceiling bays or coffers 14 for the accommodation of various ceiling mounted systems. In the construction of FIG. 2, it will be noted that the air circulating or distributing network of ducts 16 actually has the deck formed thereabout.

The air circulating duct system 16, regardless of the overall ceiling construction, while it can consist of solely supply ducts or solely return ducts, will normally incorporate both supply and return ducts arranged so as to provide an effective circulation of air through the underlying room or area.

Each bay 14 incorporating a portion of the duct system 16, whether this be every bay or selected bays, may be provided with sound absorbing acoustical material 22. This material 22 preferably lines the bay and is so arranged as to provide an effective sound deadening means whereby a substantial amount of sound is absorbed from the noise generated from the room or area below. Sound absorbing material 33 may also be placed on the air circulating duct system to absorb the noise generated by air passing through the duct system.

The ceiling construction of the invention will also incorporate appropriate illumination means 24 which may take any form, for example, fluorescent tubing as illustrated. Also, if deemed desirable for a particular installation, sound projection means 26, such as a conventional public address systems, can be provided, as well as an overhead fire extinguishing water sprinkling system 28. ln each instance, assuming a bay or eoffer ceiling, the various components will be positioned within the bays or coffers provided, or immediately adjacent thereto.

All of the above components are concealed and protected by an underlying system of filters 30 which define the under surface of the ceiling construction. These filters, removable for access to the concealed components as well as periodic replacement as required, can be in the form of elongated strips or sheets. However, such filters will normally consist of individual rectangular mats releasably mounted in appropriate rectangular frames 32 of any suitable type which are in turn either pivotally or slip mounted in the manner of conventional suspended ceiling panels and as suggested in FIGS. 1 and 2. The mats are preferably coated with an oily substance to aid in filtration.

The filters specifically act so as to entrap and extract airborne dust particles and the like from the circulating air, and are effective in either direction of air flow. As such, the various concealed lights, sound reproduction systems, fire extinguishing systems, and the like are maintained in a clean and protected environment resulting in reduced friction in the air flow. ln conjunction therewith, and particularly significant, is the fact that the acoustical sound absorbing material 22, which in almost all instances is ofa porous nature for the most effective sound absorbing capabilities, is protected against airborne dirt and maintained clean so as to retain its maximum noise absorbing capabilities. In other words, conventional sound absorbing material will, over a period of time, have the various sound absorbing pores, openings, or the like gradually filled and closed off by the absorption of foreign material therein. This in turn greatly reduces the ability of the sound absorbing material to properly function. The provision of separate filters, of a disposable and easily replaceable nature, eliminates the normally expected deterioration of the sound absorbing capabilities of the acoustical material.

The filters 30 of the invention, in addition to filtering the air flow so as to maintain the acoustical material and other components of the construction in a clean state, provide in effect a continuous lower layer on the ceiling. As such, the filters are specifically constructed so as to, while effectively filtering the air, not interfere with the operation of the remaining components. In other words, the filters 30 are capable of passing or transmitting light from the light sources 24, sound from the sound sources 26, and, should a fire emergency arise, water from the sprinkler systems 28. Additionally, the filters are so designed as to have some sound absorbing qualities with the remaining noise generated below passing through the filter to be entrapped by the sound absorbing acoustical material 22.

In order to function in this manner, the filter mats are formed of continuous filament fibers of glass, polyethylene, or polyester bonded together with an appropriate thermosetting resin which polymerizes at a temperature below the degradation point of the particular fi bers which form the matrix being bonded.

In the form of filter 30 illustrated in FIG. 3, the filter consists basically of two layers, 40 micron diameter fibers loosely woven or felted on the air entering side of the filter and 25 micron diameter fibers closely woven or felted on the air exiting side of the filter. In another form, illustrated in FIG. 4, a constant density fiber arrangement can be provided wherein fibers of approximately 30 microns in diameter are utilized throughout the extent of the filter. As previously indicated, the fibers are bonded by an appropriate thermosetting resin resulting in a self-sustaining mat which, in any reasonable size, can be supported by a peripheral frame. Should additional support be required, thin cross braces can be provided on the supporting frame. In any case, the filters are to be easily removed for replacement purposes at regular intervals. [t is contemplated that in order to function in the proposed manner, a one inch thick filter should have an air flow resistance equal to approximately 7/100 inch on a conventional water gauge. A 2 inch filter should have approximately a 1/10 inch water gauge resistance measurement.

Other features can be incorporated into the ceiling construction as contemplated. For example, the filters can be colored as desired for pleasing aesthetic effects. The filtration material may be made with pores for yet additional sound absorption. In addition, release means can be incorporated therein so as to dispense, as an example, perfumes and the like. Incidentally, it should be appreciated that the provision of the filters which can be periodically replaced enables the use of an air flow system of less overall capacity and noise emission than that which would be required were no replaceable filtering means provided.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

I claim:

1. An air circulating ceiling construction including a system inlet and exhaust ducts, sound absorbing means provided adjacent said ducts for the muffling of air flow induced noises and for absorbing noises from the room below, and filter panels mounted below said ducts and sound absorbing means and in the path of air flow to and from the room, said filter panels defining the exposed surface of the ceiling and consisting of a fibrous air pervious medium defined by micro-size fibers loosely felted in a substantially homogeneous manner and defining air passages which are the sole passages through said panels, said fibers being bonded into a self-sustaining mat with said air passages formed by and between the fibers and the fibers effecting entrapment of airborne dust particles and the like, said fibrous medium having sound transmitting capabilities whereby the sound absorbing means is maintained clean and its sound absorbing capability unimpaired.

2. The construction of claim 1 including a light source mounted above said filter panels, said filter panels being of a light passing nature and serving to conceal said light source, and to prevent dust accumulation on light bulbs and resulting light reduction.

3. The construction of claim 2 including a sound source mounted above said filter panels, said filter panels being of a sound passing nature.

4. The construction of claim 3 including a water dispensing fire extinguishing system mounted above said filter panels, said filter panels being of a water passing nature.

5. An air circulating ceiling construction including a system inlet and exhaust ducts, sound absorbing means provided adjacent said ducts for the muffling of air flow induced noises and for absorbing noises from the room below, filter panels mounted below said ducts and sound absorbing means and in the path of air flow to and from the room, said filter panels defining the exposed surface of the ceiling and effecting entrapment of airborne dust particles and the like whereby the sound absorbing means is maintained clean and its sound absorbing capability unimpaired, a light source mounted above said filter panels, said filter panels being of a light passing nature and serving to conceal said light source, and to prevent dust accumulation on light bulbs and resulting light reduction, a sound source mounted above said filter panels, said filter panels being of a sound passing nature, and a water dispensing fire extinguishing system mounted above said filter panels, said filter panels being of a water passing nature, said filter panels being formed of bonded continuous fibers approximately 25 to microns in diameter.

6. The construction of claim 4 wherein each filter panel has an air entering side and an air leaving side, said filter panels being formed of two layers of bonded continuous fibers, said bonded fibers on the entering side of each filter panel being approximately 40 microns in diameter, said bonded fibers on the leaving side of said filter panel being approximately 25 microns in diameter.

7. An air circulating ceiling construction including a system inlet and exhaust ducts, sound absorbing means provided adjacent said ducts for the muffiing of air flow induced noises and for absorbing noises from the room below, and filter panels mounted below said ducts and sound absorbing means and in the path of air flow to and from the room, said filter panels defining the exposed surface of the ceiling and effecting entrapment of airborne dust particles and the like whereby the sound absorbing means is maintained clean and its sound absorbing capability unimpaired, said filter panels being formed of bonded continuous fibers approximately to microns in diameter.

8. An air circulating ceiling construction including a system inlet and exhaust ducts, sound absorbing means rovided adjacent said ducts for the muffling of air flow induced noises and for absorbing noises from the room below, and filter panels mounted below said ducts and sound absorbing means and in the path of air flow to and from the room, said filter panels defining the exposed surface of the ceiling and effecting entrapment of airborne dust particles and the like whereby the sound absorbing means is maintained clean and its sound absorbing capability unimpaired, each filter panel having an air entering side and an air leaving side, said filter panels being formed of two layers of bonded continuous fibers, said bonded fibers on the entering side of each filter panel being approximately 40 microns in diameter, said bonded fibers on the leaving side of said filter panel being approximately 25 microns in diameter.

9. The construction of claim 1 wherein said filter panels are formed of bonded continuous fibers no greater than approximately 40 microns in diameter.

Claims

5. An air circulating ceiling construction including a system inlet and exhaust ducts, sound absorbing means provided adjacent said ducts for the muffling of air flow induced noises and for absorbing noises from the room below, filter panels mounted below said ducts and sound absorbing means and in the path of air flow to and from the room, said filter panels defining the exposed surface of the ceiling and effecting entrapment of airborne dust particles and the like whereby the sound absorbing means is maintained clean and its sound absorbing capability unimpaired, a light source mounted above said filter panels, said filter panels being of a light passing nature and serving to conceal said light source, and to prevent dust accumulation on light bulbs and resulting light reduction, a sound source mounted above said filter panels, said filter panels being of a sound passing nature, and a water dispensing fire extinguishing system mounted above said filter panels, said filter panels being of a water passing nature, said filter panels being formed of bonded continuous fibers approximately 25 to 40 microns in diameter.

7. An air circulating ceiling construction including a system inlet and exhaust ducts, sound absorbing means provided adjacent said ducts for the muffling of air flow induced noises and for absorbing noises from the room below, and filter panels mounted below said ducts and sound absorbing means and in the path of air flow to and from the room, said filter panels defining the exposed surface of the ceiling and effecting entrapment of airborne dust particles and the like whereby the sound absorbing means is maintained clean and its sound absorbing capability unimpaired, said filter panels being formed of bonded continuous fibers approximately 25 to 40 microns in diameter.

8. An air circulating ceiling construction including a system inlet and exhaust ducts, sound absorbing means provided adjacent said ducts for the muffling of air flow induced noises and for absorbing noises from the room Below, and filter panels mounted below said ducts and sound absorbing means and in the path of air flow to and from the room, said filter panels defining the exposed surface of the ceiling and effecting entrapment of airborne dust particles and the like whereby the sound absorbing means is maintained clean and its sound absorbing capability unimpaired, each filter panel having an air entering side and an air leaving side, said filter panels being formed of two layers of bonded continuous fibers, said bonded fibers on the entering side of each filter panel being approximately 40 microns in diameter, said bonded fibers on the leaving side of said filter panel being approximately 25 microns in diameter.