Note: Descriptions are shown in the official language in which they were submitted.
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CURVED CEILING PANEL
BACKGROUND
This disclosure relates to suspended ceiling systems and more particularly to
a
novel and improved system using curved ceiling panels having a curved exterior
surface in combination with a planar perimeter that is adapted to be used with
a
horizontal grid structure.
By way of background but not limitation, suspended ceiling systems typically
include grid members that provide for oppositely extending ceiling panel
support
flanges. In these systems, the edges of the ceiling panels are installed by
laying them
in the panel opening created by the grid members. There are also suspended-
ceiling
systems that have grid members, which include channels designed to grip the
vertically extending edges of metal ceiling panels. These ceiling panels are
typically
installed by snapping the flanges up into the grid member channel, and are
generally
referred to as "snap-up ceiling panels." Typical lay-in grid panels are
manufactured
to fit within a horizontal grid and are planar in nature. In order to obtain a
curved
ceiling surface in typical ceiling systems, curved panels are used in
combination with
curved ceiling grid members. The use of curved grid members to form the
ceiling
structure increases cost and difficulty of installation.
In view of the above, it should be appreciated that there is a need for a
ceiling
system that provides for a curved ceiling surface while permitting the use of
a
standard horizontal grid arrangement. The present disclosure satisfies these
and other
needs and provides further related advantages.
SUNIMARY
The disclosure may be described as a novel and improved curved suspension
ceiling system that creates the appearance of a curved or wavy ceiling surface
when
used in combination with a planar grid system. In the preferred embodiment,
the
curved panel system comprises a metallic or polymer curved panel having a
curved
exterior surface formed by a curved wall. The curved panel includes a pair of
opposed sidewalls that are attached to the curved wall and include a curved
surface
along a first edge and a substantially linear surface along a second edge. The
linear
edges each include flanges that permit the curved panel to be attached to grid
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members of the planar grid system. The curved panels are designed so that they
can
be flipped over so that the face of the curved wall can be oriented to face
above or
below the ceiling grid. During installation, the curved panels can be
alternately
flipped to form an undulating or wavy pattern to create a desired effect when
viewed
from below.
Other features and advantages of the disclosure will be set forth in part in
the
description which follows and the accompanying drawings, wherein the
embodiments
of the disclosure are described and shown, and in part will become apparent
upon
examination of the following detailed description taken in conjunction with
the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features of this disclosure and the manner of
obtaining them will become more apparent and the disclosure will be best
understood
by reference to the following description of embodiments of the disclosure
taken in
conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a ceiling system illustrating curved ceiling
panels;
FIG. 2 is a sectional view of the ceiling system, taken along lines 2-2,
illustrating the curved ceiling panels connected to a grid system;
FIG. 3 is a perspective view of the curved ceiling panel;
FIG. 4 is a top view of the curved ceiling panel;
FIG. 5 is a side elevational view of the curved ceiling panel; and
FIG. 6 is an end view of the curved ceiling panel.
DETAILED DESCRIPTION
While the present disclosure will be described fully hereinafter with
reference
to the accompanying drawings, in which a particular embodiment is shown, it is
to be
understood at the outset that persons skilled in the art may modify the
disclosure
herein described while still achieving the desired result. Accordingly, the
description
that follows is to be understood as a broad informative disclosure directed to
persons
skilled in the appropriate art and not as limitations on the present
disclosure.
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As illustrated in the drawings, Fig. 1 illustrates a portion of an assembled
suspension ceiling incorporating curved ceiling panels 10 in accordance with
the
present disclosure. In such a ceiling panel system, grid members 12 are
interconnected to form a grid structure 13. The grid members 12 are arranged
to form
openings sized to receive the curved ceiling panels 10. The grid members 12
are
suspended from the building structure by wire hangers 16 or other supporting
structures.
To create the grid structure 13, a row of parallel evenly spaced grid members
12 are suspended by the wire hangers 16. Each row of the grid members 12 are
spaced apart to accommodate the size of the curved ceiling panels 10. To
accommodate a two foot by two foot ceiling panel, the grid members 12 would be
spaced apart two feet on-center. The grid structure 13 also includes a second
set of
grid members 18 that are perpendicularly oriented in relation to the first set
of grid
members 12 to create the opening required for hanging the curved ceiling
panels 10.
The curved ceiling panels 10 are normally rectangular or square in shape, and
are preferably made out of metal or polymer. The curved ceiling panels 10 are
durable in that they are impact resistant, self-supporting do not sag when
spanned
between grid members 12. Metal and plastic polymeric material, such as
polycarbonate, are preferred since panels can be molded or stamped to include
a
desired shape or to form various edge configurations for connection to the
grid
structure 13. Alternately, among other rigid, and semi-rigid materials, glass
reinforces gypsum, wood or thermoformed fabrics may be used.
The curved ceiling pane110 used within the grid structure 13 as shown in
Figures 1 and 2 are comprised of a curved wa1120 that includes a first face 22
and
second face 24, opposing the first face 22. Depending upon the orientation of
the
curved panels 10 within the grid structure 13, either the first face 22 or the
second
face 24 may be exposed to the area below the grid structure 13. The curved
wa1120
of the curved ceiling panel 10 is curved about its length and extends from a
first edge
26 to a second edge 28 of the curved ceiling panel 10. The curved ceiling
panels 10
also includes a first sidewall 30 and a spaced apart second sidewa1132. The
first
sidewa1130 is substantially parallel to the second sidewa1130.
The first sidewa1130 of the curved ceiling panel 10 includes a relatively
linear
edge 34 and a curved edge 36. The curved edge 36 of the first sidewall 30 is
spaced
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apart from the linear edge 34 in the central region of the panel 10 but
converges with
the linear edge 34 at the endpoints 38 of the curved edge 36. The curved edge
36 is
formed by the intersection of the curved wall 20 with the first sidewall 30.
The second sidewall 32 of the panel 10 is parallel to and spaced apart from
the
first sidewall 30. The second sidewall 32 of the panel 10 includes a
relatively linear
edge 40 and a curved edge 42 as shown in Figure 5. The curved edge 42 of the
second sidewall 32 is spaced apart from the linear edge 40 in the central
region of the
panel 10 but converges with the linear edge 40 at the endpoints 44 of the
curved edge
42. The curved edge 42 is formed by the intersection of the curved wa1120 with
the
second sidewall 32.
The first and second edges 26, 28 of the panel 10 form a portion of the
perimeter of the panel 10. The first edge 26 includes a first flange 46 that
extends
outwardly from the panel 10. The first flange 46 is adapted to be connected to
the
grid members 12 of the grid structure 13 to aid in supporting the panel 10. In
a lay-in
panel arrangement, the first flange 46 is horizontally oriented and rests upon
a base
portion 58 of the grid members 12 as shown in Figure 2. When using a snap-in
panel
arrangement, the first flange 46 is adapted to be connected to a channel
portion of the
grid members 12. The second edge 28 includes a second flange 48 that extends
outwardly from the panel 10. The second flange 48 is adapted to be connected
to the
grid members 12 of the grid structure 13 to aid in supporting the panel 10 as
shown in
Figure 4.
The linear edge 34 of the first sidewall 30 of the curved panel 10 includes a
third flange 50 that extends outwardly from the curved panel 10 as shown in
Figure 3.
The third flange 50 is adapted to be connected to the grid members 12 of the
grid
structure 13 to aid in supporting the panel 10. The linear edge 40 of the
second
sidewall 32 includes a fourth flange 52 that extends outwardly from the curved
panel
10. The first, second, third and fourth flanges 46, 48, 50 and 52 form the
perimeter of
the curved ceiling panel 10. The flanges 46, 48, 50 and 52 may also include
tabs that
aid in retaining the curved ceiling panels 10 to the grid structure 13.
The curved ceiling system, as shown in Figs. 1 and 2, illustrates the curved
panels 10 connected to the grid structure 13 by use of flanges 46, 48. While
the
curved ceiling panels 10 preferably are connected to the grid structure 13
with
flanges, a hinge may be used to permit the curved ceiling panel 10 to be
pivoted to an
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open position for service above the ceiling structure 13. While flanged edges
and a
hinged edge are disclosed, other edge configurations may be used to secure the
curved
ceiling panels 10 to the grid system 13. It is beneficial to use the hinge to
support the
curved ceiling panel 10 when all metal ceiling panels become as large as 4
feet by 4
feet, because the panels become awkward to install and remove due to their
relatively
large size and weight. Further illustrations of the use of a hinge can be
found in U.S.
Patent number 6,467,228, incorporated herein by reference. When working with a
piece of sheet metal with such a large surface, any improper handling may
result in
damage to the overall finish of the ceiling panel 10. Also, by using the hinge
that
spans the width of the curved ceiling panel 10, the weight of the panel is
evenly
distributed across the entire edge of the curved panel 10, preventing rippling
that
would be apparent in the curved wal120 of the curved panel 10. Furthermore,
once
the curved ceiling panel 10 is connected to the grid meinbers 12, the curved
ceiling
panel 10 will automatically be in alignment to allow for easy closure by
pivoting the
ceiling panel 10 upward and snapping in the flanges into the grid.
The grid member 12, as shown in Figure 2, in this example 12 is fabricated out
of die-formed sheet metal. The grid member 12 after fabrication includes a
bulb
portion 56, a base portion 58 and a bridge portion 60 that connects the bulb
portion 56
and the base portion 58. The overall shape of the grid member 12 is to give
the
member 12 strength to prevent flexing. Typically, apertures (not shown) are
placed
along the length of the bridge portion 60 so that wire hangers 16 can be
threaded
through and wrapped around the bulb portion 56. Once the wire hanger 16, as
shown
in Fig. 1, which can be in the form of a wire, is threaded through an aperture
(not
shown) and around the bulb portion 56, the wire hanger 16 is wrapped around
itself
several times to prevent it from unraveling.
The bridge portion 60 typically includes slots (not shown) that allow one grid
member 12 to be connected to the second grid member 18 to form the grid
structure
13. The base portion 58, as shown in FIG. 2 is formed by bending the double
layers
of the bridge portion 60, ninety degrees outward and one hundred eighty
degrees
inward to form a planar surface. If a hinge is used, a modified grid member 12
is used
that includes a boxed channel located on the bottom portion of the grid member
12.
The hinge is formed in the curved ceiling panel 10 by die-forming the hinge
ninety
degrees upward to create an upwardly extending leg and then die-forming the
edge
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ninety degrees inward to create an inward lip. The inward lip of the hinge
rests
within the channel of the grid member 12. The flanges 46, 48, 50, 52, shown in
FIG.
2, are formed by die-forming or molding the edges 34, 36, 40, 42 of the curved
ceiling
panel 10 outward to form a horizontal surface. The ceiling panel 10 is
retained to the
grid structure 13 by positioning the flanges 46, 48, 50, 52 on the base
portion 58 of
the grid members.
The environmental area of the building structure is defined as the space
within
a building used by occupants to work or conduct other activities. It is the
inhabitable
space within a structure. From the environmental area, the curved wall 20 of
the
curved ceiling panel 10 is substantially exposed and viewable by the occupants
below.
Depending upon the orientation of the curved ceiling panel 10 within the grid
structure 13, either the first face 22 or the second face 24 will be viewable
from the
environmental area below. When the curved ceiling panel 10 is positioned with
the
curved wall 20 in an arched position, the first face 22 is viewable from
below. When
the curved ceiling panel 10 is positioned within the grid structure 13 with
the curved
wal120 in an inverted arch position, the second face 24 of the curved wall 20
is
viewable from the environmental area below.
The curved ceiling panels 10 are designed with four edges that are adapted to
be connected to the grid structure 13. The curved ceiling panels 10 can be
connected
to the grid structure 13 using various edge configurations. The edges can be
outfitted
with flanges that permit either snap in or lay in configurations.
In use the curved ceiling panels 10 are an economical solution to achieving a
unique ceiling appearance. The present arrangement permits the creation of a
wavy or
rolling ceiling appearance while utilizing easy to install planar grid
structure 13.
Using the curved ceiling panels various patterns can be formed in the ceiling
including having all panels oriented in an arched position or all panels
oriented in an
inverted arch position. Alternating the orientation of the panels in adjacent
grid
openings permits the creation of wavy or rolling patterns. Since standard
linear grid
members can be used additional hardware to secure the proper orientation of
the
panels with respect to the grid structure 13 is not required. In systems where
curved
grid members are used, it is necessary to use additional fasteners to ensure
the panels
conform to the shape of the grid members.
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While the concepts of the present disclosure have been illustrated and
described in detail in the drawings and foregoing description, such an
illustration and
description is to be considered as exemplary and not restrictive in character,
it being
understood that only the illustrative embodiments have been shown and
described and
that all changes and modifications that come within the spirit of the
disclosure are
desired and protected.
There are a plurality of advantages that may be inferred from the present
disclosure arising from the various features of the apparatus, systems and
methods
described herein. It will be noted that alternative embodiments of each of the
apparatus, systems, and methods of the present disclosure may not include all
of the
features described yet still benefit from at least some of the inferred
advantages of
such features. Those of ordinary skill in the art may readily devise their own
implementations of an apparatus, system, and method that incorporate one or
more of
the features of the present disclosure and fall within the spirit and scope of
the
invention as defined by the appended claims.
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