IP Library › Granted Patent US 11,821,205

Granted Patent B2

US 11,821,205 · App. 17/462,934 · Granted Nov 21, 2023

Modular ceiling system

Inventors: Wayne McGee (Chesterfield, MO); Steve Skikas (St. Charles, MO); Trace Woodrum (Ballwin, MO); Thomas Tall (Beaufort, MO)

Assignee: Porta-Fab Corporation

E04B9/067 E04B9/02 E04B9/127 E04B9/241

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Quick Facts

Patent No.: US 11,821,205
App. No.: 17/462,934
Granted: Nov 21, 2023
Kind: B2

External Links

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Abstract

A structural grid support system adapted for transferring seismic loads to the vertical structural supports of a modular structure. The system includes larger and longer high load capacity main runners with mechanically fastened cross tees, which transfer seismic forces without failing. The structural grid can provide a diaphragm using mechanically fastened connections in a single horizontal plane without requiring additional overhead support from the roof deck, or requiring fewer such supports. The main runners may include additional connecting elements disposed within the usable space beneath the runner (e.g., ventral threaded receivers) for attaching deployment-specific equipment or hardware, such as network cable trays.

Claims (61)

1. A main runner for use in a ceiling grid comprising:

a first end and an opposing second end, with an elongated body extending therebetween, said body having a cross-section comprising:

a hanger element generally in the configuration of a U-shape and having an open top end adapted to accept hardware for suspending said main runner from an overhead structure;

a main body element extending generally perpendicularly downward from a base of said hanger element;

a generally orthogonal I-shaped connecting element comprising:

a top element comprising a top side and an opposing bottom side, said top side of said top element connected generally perpendicularly to said main body element;

a middle element extending generally perpendicularly downward from said bottom side of said top element;

a bottom element comprising a top side and an opposing bottom side and a first distal end and an opposing second distal end, said top side of said bottom element connected generally perpendicularly to said middle element;

a first side element extending generally perpendicularly downward from said first distal end of said bottom element;

a second side element extending generally perpendicularly downward from said second distal end of said bottom element, said second side element being generally parallel with said first side element; and

a base element connected generally perpendicularly to said first side element and said second side element;

wherein said bottom element, said first side element, said second side element, and said base element define a hollow interior cavity;

wherein said top element comprises a first pair of receiving channels disposed in opposing sides thereof; and

wherein top element, said bottom element, and base element are each generally perpendicular to each of said main body element, said middle element, first side element, and said second side element.

2. The main runner of claim 1 , wherein said first pair of receiving channels are threaded.

3. The main runner of claim 1 , wherein said bottom element comprises a second pair of receiving channels disposed in opposing sides thereof.

4. The main runner of claim 3 , wherein said second pair of receiving channels are threaded.

5. The main runner of claim 1 , wherein said base element comprises a pair of opposing flanges extending laterally therefrom.

6. The main runner of claim 5 , wherein said pair of opposing flanges are sized and shaped to accept a ceiling panel on a top side thereof.

7. The main runner of claim 1 , wherein said base element comprises a receiver disposed in a bottom side thereof.

8. The main runner of claim 7 , wherein said receiver is generally perpendicularly disposed in said base element.

9. The main runner of claim 8 , wherein said receiver is threaded.

10. A modular ceiling grid system comprising:

a plurality of main runners, each main runner in said plurality of main runners having a first end and an opposing second end, with an elongated body extending therebetween, said body having a cross-section comprising:

a hanger element generally in the configuration of a U-shape and having an open top end adapted to accept hardware for suspending said each main runner beam from an overhead structure;

a main body element extending generally perpendicularly downward from a base of said hanger element;

a generally orthogonal I-shaped connecting element comprising:

a top element comprising a top side and an opposing bottom side, said top side of said top element connected generally perpendicularly to said main body element;

a middle element extending generally perpendicularly downward from said bottom side of said top element;

a first side element extending generally perpendicularly downward from said first distal end of said bottom element;

a base element connected generally perpendicularly to said first side element and said second side element;

wherein said bottom element, said first side element, said second side element, and said base element define a hollow interior cavity:

wherein said top element comprises a first pair of receiving channels disposed in opposing sides thereof; and

wherein top element, said bottom element, and base element are each generally perpendicular to each of said main body element, said middle element, first side element, and said second side element;

a plurality of cross-Ts, each cross-T in said plurality of cross-T's affixed to at least one main runner in said plurality of main runners to form a generally orthogonal ceiling grid system.

11. The modular ceiling grid system of claim 10 , wherein said plurality of main runners are connected at said first end and said second end to opposing walls of a prefabricated structure.

12. The modular ceiling grid system of claim 11 , wherein said prefabricated structure is selected from the group consisting of: an in-plant office; a data center; a clean room; a medical examination, testing, diagnostic, laboratory, or treatment room; a quarantine or isolation room; and a botanical grow room.

13. The modular ceiling grid system of claim 10 , wherein said plurality of main runners are suspended from an overhead structure by connecting said hanger elements to said overhead structure.

14. The modular ceiling grid system of claim 10 , wherein said each cross-T in said plurality of cross-Ts is affixed to a main runner in said plurality of main runners by at least one bracket.

15. The modular ceiling grid system of claim 10 , further comprising electrical, computer, or HVAC equipment installed on said modular ceiling grid system.

16. The modular ceiling grid system of claim 10 , further comprising walkable decking installed on said modular ceiling grid system.

17. A method for installing a ceiling comprising:

providing a plurality of main runners, each main runner in said plurality of main runners having a first end and an opposing second end, with an elongated body extending therebetween, said body having a cross-section comprising:

a hanger element generally in the configuration of a U-shape and having an open top end adapted to accept hardware for suspending said each main runner from an overhead structure;

a main body element extending generally perpendicularly downward from a base of said U-shaped hanger;