Ceiling panel

Abstract: A ceiling panel (20) that conceals the grid in a suspended ceiling, having opposed active edges (A, B) with profiles different from one another, and opposed passive edges. Kerfs (33, 35) at different levels in the active edges (A, B), along with a registration step (36) in the one active edge (A), permit the panel (20) to be inserted, or removed, by successive hinge actions. When installed, the panel (20) is locked to the ceiling with no visual indications on how the panel can be removed.

Description: This invention relates to a panel for use with a supporting grid in a suspended ceiling. The panel is of the type that conceals part or all of the grid, when viewed from below. Suspended ceilings are common. They use a grid of metal beams in the form of an inverted T-section, commonly of a 15/16" flange width dimension, to support the panels. The rectangular openings formed by the grid are generally either 24" x 24" or 24" x 48" with correspondingly sized panels. However, irregularly shaped and sized openings and panels are used. Dimensions may be in metric units. The present invention applies to such suspended ceilings and panels. The panels are of various ceiling substrates, such as mineral fiber, fiberglass, wood, metal, plastic, or other composition. They are positioned within the grid opening, and are supported by the grid. The panels are either of the type that expose the grid when the ceilings are viewed from below, or conceal the grid either fully or partially, when viewed from below. This invention involves those panels that conceal the grid when viewed from below. Panels for a ceiling with exposed grids have a form of upper lip extending over the top of the grid with no lip on the panel below the grid. The panel hangs from the grid, by means of this upper lip. Such panel is relatively simple to install, position and remove. These panels are not intended to be locked by themselves to the grid. Panels that conceal the grid from below, on the other hand, pose special problems, since the portion of the edge underlying the grid interferes with any simple installation, positioning, and removal. Panels that conceal the grid, however, are desirable for among other benefits, their appearance, as well as their ability to lock to the grid. The grid can be partially or totally hidden. Additionally, since the panels of this type cover the metal grid, they can have a beneficial effect during a fire, since they serve to insulate the metal from the effects of the heat, particularly where panels are of a fire retardant material, as is generally the case. Since panels that conceal generally have a lip below the grid as well as one above the grid, there is the potential for locking the panel to the grid. This is especially useful again during a fire, and even more so during a seismic disturbance. Falling panels during a quake present a serious threat to the safety of persons present below the ceiling, and particularly so where gatherings occur such as in auditoriums or public areas. Panels locked to the grid which give no visual clue to their removal procedure also provide a degree of security against unauthorized access to the space above the ceiling. Notwithstanding the desirable features of panels that conceal the grid, their use has been limited to a great degree because of problem with installation and removal. In some instances, special shaped grids must be used. In other designs, auxiliary clips or metal attachments to the grid are necessary. Generally, the space above the grid must be used in installing, or removing the panel, requiring such space to be available, thus reducing room height. In some instances, the installer must position each panel visually from below, with a resulting slowdown in installation. Even without the necessity of visual positioning during installations, in prior art panels that conceal, the installation is a relatively slow procedure. Often, in prior art, special tools were necessary to install or remove panels that lock or conceal. Prior art patents relating to panels in suspended ceilings that conceal the grid, and in some instances lock, include US-A-2,218,092, 3,640,012, 3,714,752, 3,900,997, 4,189,895, 4,696,141, 4,760,677, 4,862,663, GB-A-2 163 787 and GB-2,200,151B, and FR-1,313,963 and 1,227,191. These panels show various edge designs that engage the grid. It is the object of the invention to provide a ceiling panel for use in a suspended ceiling that has a panel supporting grid formed of inverted T-section beams, which panel can be easily installed and removed from below the ceiling without using any tool, and is stably locked in the ceiling. This object is achieved by a ceiling panel as described in claim 1 and by a subceiling according to claim 8. The panel of the present invention is easy to install in a ceiling. Two opposed active, parallel edges, different from one another in profile, without interference from at least two opposed passive edges that can be the same as one another, enable the panel to be pivoted about the one active edge in engagement with a flange, into a generally horizontal position. The panel is then shifted to engage the opposing active edge with its adjacent grid flange. During the shift, the panel slightly rotates, seats, and locks into position. In effect, the opposed active edges, each with its distinctive profile different from the other, serve successively as hinges, with the adjacent grid flange, to install the panel. Since the panel is installed in the ceiling from below with no need for access to space above the grid, higher ceiling heights are possible, and there is no interference with plenum utilities during panel installation or service. When installed, the panel conceals the supporting grid, looks the same as the other panels in the ceiling, is supported by the grid, is locked in place vertically and horizontally, provides no visual clue as to how the panel can be removed, resists removal from random efforts by individuals unknowledgeable in the unlocking procedure and strongly tends to remain in place during destructive events such as fire or seismic disturbances. The active and passive edges cannot be determined by visual inspection of the ceiling from below. The active edges can be determined in an installed panel by an upward force on the center of the panel, whereby the panel will pivot upward about the kerf in one of the active edges. The panel is also easy to remove from the ceiling, provided the removal procedure is known. Once it is known how to locate a specific edge, the installation steps are simply reversed, to remove the panel. No tools are necessary to install or remove the panel. The present invention can be used not only with rectangular panels, but also with hexagonal, octagonal, and other regular and irregular shapes. It is only necessary that the panel have two active, opposing, parallel edges having distinctive profiles, different from one another, each with the profile disclosed herein. The remaining edges of the panel are passive. Embodiments of the invention are now described with reference to the accompanying drawings. Figure 1 is a perspective view, from below, of a ceiling that uses the panel of the invention, one of which is shown in position as it is being installed. Figure 2 is a perspective view of the panel of the invention. Figure 3 is a perspective view of the panel turned by 180 degrees with regard to Figure 2. Figure 4 is a horizontal sectional view of the ceiling taken on the line 4-4 in Figure 1, showing the active edges of the panel in profile. Figure 5 is a horizontal sectional view similar to Figure 4 taken on the line 5-5 in Figure 1, showing the passive edges in profile. Figures 6A through 6D are schematic horizontal sectional views, with the active edges in profile, showing the progressive steps in installing a panel in the ceiling. Figures 7A through 7D are schematic horizontal sectional views with the active edges in profile, showing the progressive steps in removing a panel from the ceiling. Figure 8 is a partial sectional view of panels that conceal the grid to a greater degree than the panels shown in Figures 6A through 6D. Figure 9 is a partial sectional view of a further embodiment of the invention where the active edges of the panels totally conceal the grid. Figure 9A is a view similar to Figure 9 showing an alternative embodiment of an active edge, where the active edges conceal the grid. Figures 10 and 11 show a panel in partial sectional view having a locking spring. The panel 20 of the invention is of the type, which is installed in a grid ceiling 21, supported by metal grids 22 having inverted T cross-sections. Such grids 22 are generally used to form a square opening 23, of a 24" x 24" dimension as shown in Figure 1, or a rectangular opening, 24" x 48". The present invention is applicable to either such size opening, or any other size rectangular opening, as well as hexagonal, octagonal, or other regular or irregular shapes, as will later be explained. Additionally, a panel may carry a décor or fanciful design on its lower face, or a sculptured surface that provides a three dimensional effect to the ceiling. In the embodiment described below, the invention is shown on a square panel, of for instance, a 24" x 24" dimension. The panel 20 can be of any various substrates, such as mineral fiber, fiberglass, wood, metal, plastic, or other composition. The substrate however, must be capable of having formed on a panel the edge profiles disclosed herein. The thickness of the panel can be determined by forming the edges and then inserting and removing the panel to determine whether the edges resist damage, and are capable of supporting the panel in the ceiling, without being damaged. A thicker panel, however, results in the use of more material, so that an economic judgment must be exerted with respect to suitability of material used in this invention. Grid 20, as seen in cross-section in the figures has, in the well-known fashion, a bulb 25, a web 26, and a flange having sides 28 and 29. The total flange width is generally 15/16". The invention works with all size flanges. As can be seen from the detailed disclosure that follows, the profile must be correspondingly sized to accommodate the different sized flanges. The panel 20, in position in ceiling 21, has a flat top plane 31, and a flat bottom plane 32. The description of the panel in the following disclosure refers to the panel elements when the panel extend in a horizontal plane, as in a ceiling. The invention involves opposed active edges A and B, and opposed passive edges C and D, on panel 20. A and B, active edges, are different from one another in profile. Edges C and D, passive edges are alike. Both edges A and B have a horizontally extending kerf, designated 33 on edge A and 35 on edge B, intended to receive a supporting grid flange side 28 or 29. Kerf 35 on edge B has an upperside 30 that extends in a horizontal plane. The kerf 33 in edge A is thick and deep enough to slidably receive flange side 28 or 29 of the grid flange, and deep enough to permit opposite edge B to be rotated up into a position when kerf 35 in edge B aligns with its corresponding grid flange, as seen in Figure 6B. As seen, for instance, in Figure 4, edge A has a registration step 36 having a vertical riser 34 and a horizontal tread 39. Tread 39 forms the lower horizontal surface of upper lip 42 on edge A. Tread 39 is at the same level as upper side 30 of kerf 35 on edge B, which forms the lower surface of upper lip 43 on edge B. Tread 39 in edge A and upper side 30 of kerf 35 in edge B form the supporting surfaces for panel 20 when the panel is in seated position on flange sides 28 and 29, as seen in Figure 6D. Riser 34 in registration step 36 in edge A, and the inwardmost depth of kerf 35 at 53 in edge B position the panel 20 between flanges 28 and 29 as seen in Figures 4 and 6B. Wall 37 on edge C and wall 38 on edge D, likewise position panel 20 between flange sides 28 and 29 in a direction between those edges. Upper lip 42 on edge A is cut back at 55, and upper lip 43 is cut back at 56 to avoid interference with the installation and removal of panel 20 into ceiling 21. Such installation and removal will be explained. Lower lip 41 on edge B is thicker than lower lip 40 on edge A. Lower lip 45 on edge C and lower lip 46 on edge D also contribute to locking the installed panel 20 to the grid 22, as well as concealing the grid. The panel 20 is positioned horizontally within ceiling opening 23 by kerf 35, riser 34 of registration step 36, and wall 37 on edge C and wall 38 on edge D. Edges C and D also have cutouts 50 on edge C and 51 on edge D, which permit installation and removal of the panel 20 without interference from these edges. Kerfs 33 and 35 are at different levels in the thickness of the panel 20. As viewed in profile, kerf 35 is at a higher level in the panel than kerf 33. This permits a hinge action in the installation and removal of the panel as will be evident from the later explanation. The edges A, B, C, and D on the rectangular panel 20 of the invention provide means for installing, positioning, locking, unlocking, and removing the panel in and from a suspended ceiling supported by a grid. The same means used for installing and locking are used to unlock and remove the panel from the ceiling. The panel edges A, B, C, and D also have means to conceal the flanges of the supporting grid when the panel is in place in the ceiling. a) The First Step in Installing The means for installing include the kerfs 33 in edge A and 35 in edge B of the panel. The kerf 35 in edge B is at a higher level in the panel than kerf 33 in edge A. Both kerfs extend in horizontal planes. The panel 20 is first brought into position toward the ceiling in an inclined position, as shown in Figures 1 and 6A, with edge A uppermost. As seen in Figure 6B, the panel 20 is installed by first engaging the kerf 33 in edge A to form with the grid flange side 28, a hinge to pivot the panel 20 to a generally horizontal position in the ceiling 21, against the grid 22, wherein lower lip 41 on edge B abuts flange side 29. At this point, the kerf 35 in edge B will align with the adjacent flange side 29. b) Second Step in Installing and Positioning The entire panel is then shifted, or translated, toward the right as seen in Figure 6C toward edge B to seat the kerf 35 in edge B on its adjacent flange side 29 on the grid 22. As this shift occurs, the kerf 33 in edge A slides away from and out of its adjacent flange, permitting edge A to drop until it reaches the tread 39 of registration step 36, as seen in Figure 6D. The panel 20 now lies in the horizontal plane of the ceiling, since the level of the tread 39 of the registration step 36 in edge A is the same as that of the upper side 30 of kerf 35 in edge B, as seen in Figure 6D. The panel 20 can be slightly shifted back to the left against the vertical riser 34 of registration step 36, in what in effect is a feedback effect. This enables the installer to readily and virtually automatically minutely position the panel horizontally with a minimum of visual judgment, using simply a technique of feel. c) Locking The kerf 35 in edge B, the registration step 36 including riser 34 and tread 39 in edge A, vertical walls 37 and 38 on edges C and D, and lips 40 to 43, 45 and 46 on edges A, B, C, and D, all act to lock the panel 20 to the grid 22. d) Removal When viewed from below, the grid 22 is partially concealed in the embodiment described or totally concealed in an embodiment described later. The panels 20 give no clue as to how they were installed, or how they can be removed. For removal, the steps necessary to install the panel 20 are reversed. The remover cannot determine by sight the edge on which to begin the removal procedure, since the panel 20 gives no clue. Indiscriminate efforts to lift or shift the panel are resisted by the panel, which is locked in position. It is necessary to know the removal procedure, which involves an exploratory gentle lift upward on the panel, preferably at the center, to determine which edge moves the most. The edge that moves the most is edge A. Thus one knowledgeable in the removal process can begin the removal procedure knowing the directions required to maneuver the panel. The panels 20 are removed in steps opposite to that in installation. To know where to begin, however, one must know which is edge A. Random exploration without knowing what one is looking for does not cause the panels to unlock. When a slight upward force is exerted on the center of the panel, edge A will move slightly upward about the kerf in edge B as a hinge as seen in Figure 7A. There is no interference from edges C and D to this movement. One can then proceed with removal, based on the reversal of the installation steps. The panel 20 is shifted to the left, as seen in Figure 7B. This permits edge B to drop out of the grid as seen in Figure 7C. Panel 20 can then fall free, as seen in Figure 7D. In Figure 8, there is shown an alternative embodiment that conceals more of the grid than that of the embodiment described earlier. Lower lip 40' on edge A has a cutout 47', and lower lip 41' on edge B has a cut-out 48', which permit the insertion and removal procedure described above to take place without interference. In Figure 9, cutouts 47'' and 48" in lower lips 40" and 41'' again permit installation and removal of the panel, where the panels totally conceal the grid. In Figure 9A, cutout 48'' is beveled at 59 to yield more space than the square cutout of Figure 9. It is important to note that there remains above cutouts 47" and 48'' extended surfaces 65' and 65''. These surfaces serve to guide kerf 33 and 35 into alignment with the-adjacent grid flange and contribute to the feedback positioning aspect of the invention. Lower lips 40' and 41' in the embodiment of Figure 8, and lips 40" and 41'' in the embodiment of Figure 9 are suitably extended to provide the degree of grid concealment desired. Lower lips 45 and 46 on passive edges C and D are also modified to provide the degree of grid concealment desired. Any or all of the lower lips in any of the embodiments of the invention may be of irregular shape, such as scalloped, when viewed from below, to provide a further decorative effect to the ceiling. Figure 10 and 11 show an embodiment that uses a security spring 52 to increase the upward pressure necessary to lift edge A during the removal procedure. The convex compression spring 52 of inverted U shape extends lengthwise in the edge A. Unless increased upward pressure is exerted on edge A, the spring interferes with the entry of the flange into kerf 33 on edge A, as shown in Figure 7B of the removal process. Figure 10 shows the spring 52 in relaxed form with the panel installed in the ceiling. Figure 11 shows the spring 52 in compressed form in the position shown corresponding to Figure 7A of the removal procedure. The invention can be used on panels with shapes other than rectangular. Such shapes must have opposed active edges A and B with the profiles disclosed above. The remaining edges must all be passive, with no upper lips. Such shapes will have at least two opposed passive edges C and D, each of which is positioned between the active edges A and B.

Claims: A panel (20) for use in a suspended ceiling (21) that has a panel supporting grid (22) formed of inverted T-section beams having flanges (28, 29), which panel (20), when extending horizontally, has opposing active parallel edges (A, B), each of which has a profile different from the other, at least two opposing passive edges (C, D), a horizontal kerf (33) in the profile of the one active edge (A) that extends along the edge (A), a horizontal kerf (35) having an upper side (30) in the profile of the other active edge (B) that extends along the edge (B) above the level of the kerf (33) in the profile of the one active edge (A), a registration step (36) having a vertical riser (34) and a horizontal tread (39) in the profile of the one active edge (A) that extends along the one active edge (A) above the level of the kerf (33) in the one active edge (A), the tread (39) being at the same level as the upper side (30) of the kerf (35) in the other active edge (B), lower lips (40, 41) on at least the active edges (A, B) of the panel (20) that conceal a portion of the grid (22), a vertical wall (37, 38) on the passive edges (C, D) of the panel (20), and an upper lip (42) on the one active edge (A) having an under side formed by the tread (39) of the registration step (36), and an upper lip (43) on the other active edge (B) formed by the upper side (30) of the kerf (35), such upper lips (42, 43) having lower surfaces (39, 30) at the same level, when the panel (20) extends in a horizontal plane, that vertically support the panel (20) in the ceiling (21) by bearing upon the adjacent grid flanges (28,29), wherein the kerfs (33, 35) in the active edges (A, B) successively form hinge means with the grid flange (28, 29) to removably install the panel (20) in the ceiling (21), and wherein the kerfs (33, 35), lips (42, 43), walls (37, 38), and tread (39) and riser (34) of the registration step (36) form means to removably lock the panel (20) in the ceiling grid (22). A panel of claim 1 having a rectangular, an octagonal, a hexagonal or an irregular shape. A panel of claim 1 or 2 that has a lower lip (45, 46) on at least some of the passive edges (C, D) of the panel (20). A panel of one of the claims 1 to 3, wherein the lower lips (40'', 41'') conceal all of the grid (22). A panel of one of the claims 1 to 4, having a décor on the lower face of the panel or a sculpted lower face on the panel. A panel of one of the claims 1 to 5 wherein the kerfs (33, 35) in the active edges (A, B) successively form hinge means to remove the panel (20) from the ceiling (21). A panel of one of the claims 1 to 6, wherein the tread (39) and riser (34) in the registration step (36) as well as the surfaces adjacent the kerfs (33, 35) in the active edges (A, B) provide means for a feedback in positioning the panel (20) during installation. A horizontal suspended ceiling (21) having a grid of inverted T-section beams having flanges (28, 29), and panels (20) according to any of the preceding claims supported by the grid flanges (28, 29).

Inventors: BODINE DARRYL C, BODINE, DARRYL C.
Applicants: ARMSTRONG WORLD IND INC, ARMSTRONG WORLD INDUSTRIES, INC.
Application year: 1999
Main classification: E04B9
IPC codes: E04B9