US20060016145A1

US20060016145A1 - Curved ceiling panel

Info

Publication number: US20060016145A1
Application number: US10/897,480
Authority: US
Inventors: Deborah Lonneman
Original assignee: USG Interiors LLC
Current assignee: USG Interiors LLC
Priority date: 2004-07-23
Filing date: 2004-07-23
Publication date: 2006-01-26
Also published as: KR20070054194A; NO20070713L; EP1774116A2; JP2008507643A; CN1989306A; CA2572571A1; ZA200700226B; MX2007000652A; WO2006022889A2; RU2007106888A; WO2006022889A3

Abstract

A curved suspension ceiling panel that creates the appearances of a curved or wavy ceiling surface when used in combination with a planar grid system. The curved suspension ceiling panel comprises a curved exterior surface. The curved panel includes a pair of opposed sidewalls that are attached to the curved exterior surface and includes a curved surface along a first edge and a substantially linear surface along a second edge. The linear edges include a flange that permits the panel to be attached to grid members of a planar grid system. The curved panels are designed so that they can be inverted within the grid so that the curved exterior surface is above the grid members. During installation, the curved panels can be arranged to form an undulating or wavy pattern to create a desired effect when viewed from below.

Description

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.

SUMMARY

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 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.
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 panel 10 used within the grid structure 13 as shown in FIGS. 1 and 2 are comprised of a curved wall 20 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 wall 20 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 sidewall 32. The first sidewall 30 is substantially parallel to the second sidewall 30.
The first sidewall 30 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 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 FIG. 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 wall 20 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 FIG. 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 FIG. 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 FIG. 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 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. Pat. No. 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 wall 20 of the curved panel 10. Furthermore, once the curved ceiling panel 10 is connected to the grid members 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 FIG. 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 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 wall 20 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.
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.

Claims

1. A suspended curved panel ceiling system for connection to a structure comprising:

a plurality of linear grid members intersecting to form a horizontal grid;

a plurality of curved panels adapted to be connected to said grid, said curved panels having a first upwardly extending side and a second upwardly extending side interconnected by a curved wall, said curved wall having a first face and a second face, said first and second sides each having a curved edge and a substantially linear edge;

first and second flanges formed along the substantially linear edges of each of said sides, said first and second flanges adapted to support said curved panels within said horizontal grid.

2. The suspended curved panel ceiling system of claim 1, wherein the curved wall terminates at a first edge and a second edge.

3. The suspended curved panel ceiling system of claim 2, wherein the first and second edges each include third and forth flanges formed along the first and second edges, said third and forth flanges adapted to support said curved panels within said horizontal grid.

4. The suspended curved panel ceiling system of claim 1, wherein said first and second flanges include tabs adapted to support and retain the position of the curved panels within said horizontal grid.

5. The suspended curved panel ceiling system of claim 1, wherein said curved panels are oriented in a first position within the horizontal grid wherein said first face of said curved wall is viewable from below said horizontal grid

6. The suspended curved panel ceiling system of claim 1, wherein said curved panels are oriented in a second position within the horizontal grid wherein said second face of said curved wall is viewable from below said horizontal grid.

7. The suspended curved panel ceiling system of claim 1, wherein said curved panel is fabricated from metal.

8. The suspended curved panel ceiling system of claim 1, wherein said curved panel is fabricated from a polymer.

9. A suspended curved panel ceiling system for connection to a structure comprising:

a plurality of linear grid members intersecting to form a horizontal grid;

snap-in flanges formed along the substantially linear edges of each of said sides, said snap-in flanges adapted to support said curved panels within said horizontal grid.

10. The suspended curved panel ceiling system of claim 9, wherein said curved ceiling panel further includes a hinge adapted to be connected to said linear grid members and adapted to permit said curved ceiling panel to be pivoted from a closed position to an open position without requiring removal of said curved ceiling panel from said grid.

11. A curved ceiling panel for use with a suspended ceiling, said curved ceiling panel comprising:

a curved wall having a first face and a second face;

a first upwardly extending sidewall, adjacent to said curved wall, said first sidewall having a curved edge and a substantially linear edge;

a second upwardly extending sidewall, adjacent to said curved wall and opposing said first sidewall, said first sidewall and said second sidewall are interconnected by said curved wall, said second sidewall having a curved edge and a substantially linear edge;

a first substantially linear flange extending outwardly from said linear edge of said first sidewall;

a second substantially linear flange extending outwardly from said linear edge of said second sidewall.

12. The curved ceiling panel of claim 11, wherein said curved wall having a pair of edges terminating in a plane passing through said first and second linear flanges.

13. The curved ceiling panel of claim 12, wherein said edges of said curved wall each include a substantially linear flange.

14. The curved ceiling panel of claim 13, wherein said flanges are interconnected to form the perimeter of said curved ceiling panel.

15. The curved ceiling panel of claim 13, wherein said flanges all lie in a common plane.

16. The curved ceiling panel of claim 11, wherein said curved ceiling panel is fabricated out of metal.

17. The curved ceiling panel of claim 11, wherein said curved ceiling panel is fabricated out of a polymer.

18. A curved ceiling panel for use with a suspended ceiling, said curved ceiling panel comprising:

a curved wall having a first face and a second face;

snap-in flanges formed along said edges of said panel, said snap-in flanges adapted to support said curved panels within said horizontal grid.

19. The curved ceiling panel of claim 18, wherein said curved ceiling panel includes a hinge located along an edge of the curved ceiling panel.

20. A suspended curved panel ceiling system for connection to a structure comprising:

a plurality of linear grid members intersecting to form a horizontal grid, said linear grid members having a horizontal member and a vertical member;

a plurality of curved ceiling panels having an arcuate wall extending from a first edge to a second edge of said curved ceiling panels, said arcuate wall having a first face and a second face;

a first sidewall connected to said arcuate wall, where said interconnection of said first sidewall with said arcuate wall forms a curved edge, said first sidewall extending away from said first face of said arcuate wall and having a third edge perpendicularly oriented to said first and second edges, said third edge including a substantially linear flange adapted to be connected to said grid members;

a second sidewall connected to said arcuate wall, where said interconnection of said second sidewall with said arcuate wall forms a curved edge, said second sidewall extending away from said first face of said arcuate wall and having a fourth edge perpendicularly oriented to said first and second edges and parallel to said third edge, said fourth edge including a substantially linear flange adapted to be connected to said grid members.

21. The suspended curved panel ceiling system of claim 20, wherein said first and second edges of said curved ceiling panel each include a substantially linear flange adapted to be connected to said grid members.

22. The suspended curved panel ceiling system of claim 20, wherein said flanges include tabs adapted to support and retain the position of the curved panels within said horizontal grid.

23. The suspended curved panel ceiling system of claim 20, wherein said curved panels are oriented in a first position within the horizontal grid wherein said first face of said arcuate wall is viewable from below said horizontal grid.

24. The suspended curved panel ceiling system of claim 20, wherein said curved panels are oriented in a second position within the horizontal grid wherein said second face of said arcuate wall is viewable from below said horizontal grid.

25. The suspended curved panel ceiling system of claim 20, wherein said curved panel is fabricated from metal.

26. The suspended curved panel ceiling system of claim 20, wherein said curved panel is fabricated from a polymer.

27. A suspended curved panel ceiling system for connection to a structure comprising:

a first sidewall connected to said arcuate wall, where said interconnection of said first sidewall with said arcuate wall forms a curved edge, said first sidewall extending away from said first face of said arcuate wall and having a third edge perpendicularly oriented to said first and second edges, said third edge including a snap-in flange adapted to be connected to said grid members;

a second sidewall connected to said arcuate wall, where said interconnection of said second sidewall with said arcuate wall forms a curved edge, said second sidewall extending away from said first face of said arcuate wall and having a fourth edge perpendicularly oriented to said first and second edges and parallel to said third edge, said fourth edge including a snap-in flange adapted to be connected to said grid members.

28. The suspended curved panel ceiling system of claim 27, wherein said curved ceiling panel further includes a hinge adapted to permit said curved ceiling panel to be pivoted from a closed position to an open position without requiring removal of said curved ceiling panel from said grid.