Abstract:
A ceiling system including vertically oriented panel structures. The ceiling system may include a panel structure having first and second exposed major surfaces and a peripheral edge. A first mounting element may be coupled to the panel structure. The first mounting element may include a first portion embedded between the first and second exposed major surfaces of the panel structure and a second portion protruding from the peripheral edge of the panel structure. The second portion of the first mounting element may include a connection feature for attaching to an overhead support member. Each panel structure may have two of the mounting elements coupled thereto, and each of the mounting elements may be configured for attachment to a different overhead support member. A plurality of the panel structures may be vertically suspended from the overhead support members.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a continuation of U.S. patent application Ser. No. 14/204,299, filed Mar. 11, 2014, which is a continuation of U.S. patent application Ser. No. 13/474,077, filed on May 17, 2012, now U.S. Pat. No. 8,695,296, which in turn claims the benefit of U.S. Provisional Patent Application Ser. No. 61/486,991, filed on May 17, 2011, the entireties of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention is directed to a ceiling system having vertically extending acoustical ceiling panels. 
       BACKGROUND OF THE INVENTION 
       [0003]    In many commercial buildings, it is desirable to alter room acoustics by providing vertically extending ceiling components intended to absorb sound waves to diminish room noise. In addition, vertically extending panels may be used to aesthetically separate areas of a large space with overhead panels or decorative valances projecting downward from a ceiling. These overhead panels are also referred to as soffits, valances, and bulkheads in different settings. Additionally, overhead panels may be connected to a ceiling to provide a vertical mounting surface for advertising information, menu information, or other displays in various retail establishments. 
         [0004]    Generally, vertically extending panels are mounted using wires which are directly mounted to the ceiling. However, as the panels are mounted with wires or the like, the repair and replacement of the panels is made difficult, as there is no easy method of removing the panels from the wires. In addition, as the panels are mounted directly to the ceiling, in order to move or rearrange the panels requires that the wires be removed from the ceiling and reaffixed to the ceiling in a different location. This is both time consuming and costly. In addition, depending on the duct work, lighting, etc. found in the ceiling, the mounting of the panels in the proper position may be difficult to accomplish. 
         [0005]    It would, therefore, be beneficial to provide mounting hardware and a mounting system which allowed the vertical panels to be easily removed and replaced, thereby allowing the repair or replacement of damaged panels. It would also be beneficial to provide mounting hardware and a mounting system which allows for the repositioning of the panels as needed. 
       SUMMARY OF THE INVENTION 
       [0006]    A ceiling system including vertically oriented panel structures. The ceiling system may include a panel structure having first and second exposed major surfaces and a peripheral edge. A first mounting element may be coupled to the panel structure. The first mounting element may include a first portion embedded between the first and second exposed major surfaces of the panel structure and a second portion protruding from the peripheral edge of the panel structure. The second portion of the first mounting element may include a connection feature for attaching to an overhead support member. Each panel structure may have two of the mounting elements coupled thereto, and each of the mounting elements may be configured for attachment to a different overhead support member. A plurality of the panel structures may be vertically suspended from the overhead support members. 
         [0007]    In one aspect, the invention can be a ceiling system comprising: a panel structure having a first exposed major surface, a second exposed major surface, and a peripheral edge extending between the first and second exposed major surfaces of the panel structure; and a first mounting element comprising a first portion embedded between the first and second exposed major surfaces of the panel structure and a second portion protruding from the peripheral edge of the panel structure, the second portion comprising at least one connection feature configured for attachment to an overhead support member to suspend the panel structure with the first and second exposed major surfaces in a vertical orientation relative to a plane of a ceiling. 
         [0008]    In another aspect, the invention can be a ceiling system comprising: a first overhead support member extending along a first longitudinal axis; a second overhead support member extending along a second longitudinal axis that is parallel to the first longitudinal axis; a first panel structure having a first exposed major surface, a second exposed major surface, and a peripheral edge extending between the first and second exposed major surfaces; a first mounting element comprising a first portion coupled to the first panel structure and a second portion coupled to the first overhead support member; and a second mounting element comprising a first portion coupled to the first panel structure and a second portion coupled to the second overhead support member; and wherein the first panel structure is vertically suspended from the first and second overhead support members. 
         [0009]    Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of an exemplary mounting hardware according the invention. 
           [0011]      FIG. 2  is an alternate perspective view of the exemplary mounting hardware shown in  FIG. 1 . 
           [0012]      FIG. 3  is an end view of the exemplary mounting hardware shown in  FIG. 1 . 
           [0013]      FIG. 4  is a side view of the exemplary mounting hardware shown in  FIG. 1 . 
           [0014]      FIG. 5  is a top view of the exemplary mounting hardware shown in  FIG. 1 , with the teeth shown in phantom. 
           [0015]      FIG. 6  is a perspective view of two panels positioned proximate a support member, with one of the mounting hardware shown in an open position and the other mounting hardware shown in a closed position. 
           [0016]      FIG. 7  is an end view of the two panels, support member and mounting hardware shown in  FIG. 6 . 
           [0017]      FIG. 8  is a perspective view of an alternate exemplary mounting hardware according the invention. 
           [0018]      FIG. 9  is an end view of the exemplary mounting hardware shown in  FIG. 8 . 
           [0019]      FIG. 10  is a side view of the exemplary mounting hardware shown in  FIG. 8 . 
           [0020]      FIG. 11  is a bottom view of the exemplary mounting hardware shown in  FIG. 8 . 
           [0021]      FIG. 12  is a perspective view of a panel positioned proximate to and mounted on two support members. 
           [0022]      FIG. 13  is a perspective view of an alternate exemplary mounting hardware according the invention. 
           [0023]      FIG. 14  is a side view of the exemplary mounting hardware shown in  FIG. 13 . 
           [0024]      FIG. 15  is an end view of the exemplary mounting hardware shown in  FIG. 13 . 
           [0025]      FIG. 16  is a bottom view of the exemplary mounting hardware shown in  FIG. 13 . 
           [0026]      FIG. 17  is a perspective view of a panel mounted on the support member using the mounting hardware of  FIG. 13 . 
           [0027]      FIG. 18  is a perspective view of numerous panels mounted on the support member. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0028]    The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
         [0029]    It will be understood that spatially relative terms, such as “vertical”, “horizontal”, “upper”, “lower” and the like, may be used herein for ease of description to describe one element&#39;s or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “upper” elements or features would then be oriented “lower” than the other elements or features. Thus, the exemplary term “upper” can encompass both an orientation of upper and lower. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
         [0030]      FIGS. 1 through 7  illustrate an exemplary embodiment of mounting hardware  10  and a mounting system  12  for mounting a vertical panel  14  to a structural support member  16  which is mounted to a ceiling or the like. The panels may be used for different purposes, including, but not limited to improving the acoustics of the space, aesthetically separating areas of a large space, or providing a vertical mounting surface for advertising information, menu information, or other displays in various retail establishments. 
         [0031]    In accordance with one exemplary embodiment of the invention, the mounting system  12  provides a platform for mounting at least one overhead, vertical panel  14  that is supported on the support member  16 , as will be discussed in further detail below. The overhead panel  14  drops down in a generally vertical orientation from the plane of the ceiling and can be combined with additional panels  14  or used individually.  FIGS. 6 and 7  illustrate a perspective view of the overhead mounting system  12  in accordance with one exemplary embodiment. The mounting system  12  includes one or more support members  16 , the mounting hardware  10 , and one or more panels  14 . 
         [0032]    The panels  14  are any known panels which perform the desired function. As is best shown in  FIGS. 6, 7 and 12 , in general, the panels are made from lightweight material having a first surface  20  and an oppositely facing second surface  22 . A mounting surface or edge  24  extends between the first surface  20  and the second surface  22 . In the exemplary embodiment shown, the panels  14  are rectangular, however, the panel can take any suitable shape, length, or width. While other embodiments may be used, in one example the panel  14  contains a cellular core having first and second side walls that are covered by a veneer or laminated outer skin. The veneer or outer skin may be any color according to the aesthetic desired. The cellular core may be made of a foam material, such as, but not limited to polystyrene that allows the vertical panel to be lightweight, for example, around 1-2 pounds per linear foot of elongate length. The outer skin may be formed of a suitable lightweight material, such as, but not limited to, material having the acoustic properties required, high impact polystyrene or expanded PVC. The type of material will depend upon the application for which the panel is to be used. 
         [0033]    As is best shown in  FIGS. 6, 7 and 12 , in the exemplary embodiment shown, the support members  16  have a modified I-shaped cross-section, which is most clearly shown in  FIG. 6 . The support member  16  has a top mounting section  30  having a slot  32  for receiving an end  34  of a mounting wire  36  which is mounted to the ceiling or the like. However, other configurations of the top mounting section  30  and other methods of mounting the support member  16  to the ceiling can be used without departing from the scope of the invention. A vertical flange  38  extends between the mounting section  30  and horizontal cross members or flanges  40 ,  42 . As shown in the alternate embodiment of  FIG. 12 , locating slots  43  may also be provided periodically along the vertical flange  38 . 
         [0034]    According to the exemplary embodiment, the mounting hardware or mounting clip  10  includes an upper generally horizontal plate  50  with a support member receiving portion or flange receiving portion or hook arm  52  which extends from one end thereof. The hook arm  52  has a lead-in surface  54  and a slot  56 . Extending from the other end of the horizontal plate  50  is a movable mounting section  58 . The movable mounting section  58  has connection legs  60  which extend between the plate section  50  and the mounting section  58 , the legs  60  being configured to allow the mounting section  58  to rotate about the plate section  50 . Specifically, the mounting section  58  is rotatable about a first rotational axis B-B. The mounting section  58  has a mounting flange  62  with a screw receiving opening  64  which extends therethrough. As shown in the alternate exemplary embodiment of  FIG. 8 through 12 , a locating tab  67  may also be provided on the mounting section  58 . 
         [0035]    The plate section  50  has a first edge  66  and an oppositely facing second edge  68 . A plate axis A-A extends between the first edge  66  and the second edge  68 , as illustrated in  FIG. 8 . The first rotational axis B-B about which the mounting section  58  rotates is substantially parallel to the plate axis A-A ( FIG. 8 ). A first vertical sidewall section  70  extends downwardly from the plate section  50  at the first edge  66 . A second vertical sidewall section  72  extends downwardly from the plate section  50  at the second edge  68 . The first and second vertical sidewall sections  70 ,  72  extend from the plate section  50  such that the first and second vertical sidewall sections  70 ,  72  are allowed to rotate or pivot about the plate section  50  allowing the first and second vertical sidewall sections  70 ,  72  to be moved between an open and a closed position. More specifically, the first vertical sidewall section  70  is rotatable about a second rotational axis C-C and the vertical sidewall section  72  is rotatable about a third rotational axis D-D. The second rotational axis C-C and the third rotational axis D-D are substantially traverse to the plate axis A-A ( FIG. 8 ). The plate section  50  and the first and second vertical sidewall sections  70 ,  72  form a panel mounting section. The first and second vertical sidewall sections  70 ,  72  include a plurality of teeth  74 , which, in the exemplary embodiment shown, are also formed along the length of the sidewall sections  70 ,  72  proximate the edge of the first and second vertical sidewall sections  70 ,  72  which are furthest from the plate section  50 . The teeth  74  are substantially in alignment on both the first and second vertical sidewall sections  70 ,  72  so that the teeth  74  are in general vertical alignment with each other in elevation when the first and second vertical sidewall sections  70 ,  72  are moved to the closed position, as will be more fully described. However, other configurations of the teeth  74  are possible without departing from the scope of the invention. 
         [0036]    An optional opening  76  may be provided in the first and second vertical sidewall sections  70 ,  72 . This opening is shown in the embodiment illustrated in  FIGS. 8 through 12 , however, the opening may be provided in other embodiments, including, but not limited to the embodiment shown in  FIGS. 1 through 7 . The openings  76  permit mounting hardware  78 , such as, but not limited to, a nut and bolt, to extend through the openings. 
         [0037]    Referring to  FIGS. 6, 7 and 12 , the mounting hardware or mounting clips  10  cooperate with the support members  16  to mount the panels  14  to the support members  16  and indirectly to the ceiling. The hook arm  52  of each respective mounting clip  10  is configured to wrap around a respective flange  40 ,  42  of the support member  16 . The respective flange  40 ,  42  is guided into the slot  56  by lead-in surface  54 . Once the respective flange  40 ,  42  is positioned in the slot  56 , the movable mounting section  58  is rotated or pivoted about the connection legs  60 , thereby allowing the mounting flange  62  to be moved proximate the vertical flange  38 . As this occurs, the locating tab  67  may be inserted into a respective locating slot  37  to help properly position the mounting clip  10  relative to the support member  16 . With the mounting flange  62  positioned proximate the vertical flange  38 , a screw may be inserted into either the screw receiving opening  64  or the screw receiving opening  65 , thereby causing the mounting clips  10  to be securely fastened and positioned relative to the support members  16 . The cooperation of the hooked arm  52  and the mounting flange  62  prevents the movement of the mounting clip  10  is a direction which is perpendicular to the longitudinal axis of the support member  16 . The use of the screw prevents the movement of the mounting clip  10  is a direction which is essentially parallel to the longitudinal axis of the support member  16 . 
         [0038]    With the mounting clip  10  properly mounted and maintained in position on the support member  16 , the panel  14  is moved into engagement with the mounting clip  10 . In order to facilitate the movement of the panel  14  into the mounting clip  10 , the first and second vertical sidewall sections  70 ,  72  are spread apart in the open position. In this position, the first and second vertical sidewall sections  70 ,  72  are spread apart a distance greater than the width of the panel  14 , thereby allowing the panel  14  to be inserted until is positioned proximate to or engages the plate section  50 . 
         [0039]    With the panel  14  properly inserted between the first and second vertical sidewall sections  70 ,  72 , the first and second vertical sidewall sections  70 ,  72  are rotated inward, toward each other, thereby moving the first and second vertical sidewall sections  70 ,  72  from the open position to the closed position. As this occurs the teeth  74  engage and pierce the panel  14 . As the teeth  74  dig into the panel and are maintained in this position when the first and second vertical sidewall sections  70 ,  72  are in the closed position, the panel is maintained in position relative to the mounting clips  10  and the support member  16 . The configuration of the first and second vertical sidewall sections  70 ,  72  allows the first and second vertical sidewall sections  70 ,  72  to be rotate using a hand tool such as a pliers or the like. This allows the first and second vertical sidewall sections  70 ,  72  to exhibit a sufficient force on the panel  14  when the first and second vertical sidewall sections  70 ,  72  are in the closed position to maintain the panel  14  in position. Additionally, if the optional hardware  78  is used, the hardware provides additional support to the panel  14  and prevents the first and second vertical sidewall sections  70 ,  72  from moving back toward the open position. This provides additional safety in areas which have increased seismic activity. 
         [0040]    Depending upon the configuration and size of the panels  14 , each mounting clip  10  is long enough to provide sufficient teeth  74  to support the weight of the panel  10  in the vertical position or a combination mounting clips  10  are sufficient to support the weight of the panel  10  in the vertical position. 
         [0041]    In the exemplary embodiments, if the screw is loosened, the mounting clips  10  may slide freely along the support member  16 . This allows the mounting clips, and ultimately the panels  14 , to be positioned and repositioned in the appropriate location to achieve the desired acoustic properties or the desired aesthetics. 
         [0042]    While the exemplary embodiment described that the mounting clips  10  are mounted on the support member  16  first and the panels  14  are then mounted to the mounting clips  10 , this is just one exemplary method of assembly. As one exemplary alternative, the panels  14  may be mounted to the mounting clips  10  prior to the mounting clips being mounted to the support member  16 . 
         [0043]    Another alternate exemplary embodiment, not shown, has first and second vertical sidewall sections with no teeth. The mounting hardware extends through the openings provides the support for the panel. In this embodiment the first and second vertical sidewall sections are fixed and do not move between and open and a closed position. 
         [0044]    Another alternate exemplary embodiment is illustrated in  FIGS. 13 through 18 . The mounting system  112  provides a platform for mounting at least one overhead, vertical panel  114  that is supported on the support member  116 , as will be discussed in further detail below. The overhead panel  114  drops down in a generally vertical orientation from the plane of the ceiling and can be combined with additional panels  114  (as shown in  FIG. 17 ) or used individually.  FIG. 18  illustrates a perspective view of the overhead mounting system  112  in accordance with this exemplary embodiment. The mounting system  112  includes one or more support members  116 , the mounting hardware  110 , and one or more panels  114 . 
         [0045]    The panels  114  are made by joining two panels  115 . The panels  115  any known panels which perform the desired function. In general, each panel  115  is made from lightweight material having a first surface  120  and an oppositely facing second surface  122 . A mounting surface or edge  124  extends between the first surface  120  and the second surface  122 . In the exemplary embodiment shown, the panels  114  are rectangular, however, the panel can take any suitable shape, length, or width. While other embodiments may be used, in one example the panel  114  contains a cellular core having first and second side walls that are covered by a veneer or laminated outer skin. The veneer or outer skin may be any color according to the aesthetic desired. The cellular core may be made of a foam material, such as, but not limited to polystyrene that allows the vertical panel to be lightweight, for example, around 1-2 pounds per linear foot of elongate length. The outer skin may be formed of a suitable lightweight material, such as, but not limited to, material having the acoustic properties required, high impact polystyrene or expanded PVC. The type of material will depend upon the application for which the panel is to be used. 
         [0046]    In the exemplary embodiment shown, the support members  116  have a modified I-shaped cross-section, which is most clearly shown in  FIGS. 17 and 18 . The support member  116  has a top mounting section  130  having a slot  132  for receiving and end  134  of a mounting wire  136  which is mounted to the ceiling or the like. However, other configurations of the top mounting section  130  and other methods of mounting the support member  116  to the ceiling can be used without departing from the scope of the invention. A vertical flange  138  extends between the mounting section  130  and horizontal cross members or flanges  140 ,  142 . Locating slots  143  may also be provided periodically along the vertical flange  138 . 
         [0047]    According to the exemplary embodiment, the mounting hardware or mounting clip  110  includes a generally vertical plate section or panel mounting section  150  with a support member receiving portion or hook arm  152  which extends thereof. Extending from a portion of the hook arm  152  is a movable mounting section  158 . The movable mounting section  158  has connection legs  160  which extend between the hook arm  152  and the mounting section  158 , the legs  160  being configured to allow the mounting section  158  to rotate about the hook arm  152 . The mounting section  158  has a mounting flange  162  with at least one screw receiving opening  164  which extends therethrough. More than one screw receiving opening  164  may be provided to allow the mounting section  158  to be bent to accommodate different support members  116  and still be secured thereto. A locating tab  167  may also be provided on the mounting section  158 . 
         [0048]    The configuration of the hook arm  152  is designed to allow the hook arm  152  to be inserted on standard grid, U-profiles, I-beam carrying members, peaked roof bulb design and other such configurations. 
         [0049]    The plate section  150  has openings  166  which extend therethrough. The openings  166  allow adhesive to flow therethrough, as will be more fully described. Alignment notches  168  and a mounting opening  170  are also provided on the plate section  150 . Projections or teeth  174  (as best shown in  FIGS. 13 through 15 ), extend from both sides of the plate section  150 . In the exemplary embodiment shown, the teeth  174  are formed along the edge of the plate section  150  which is furthest from the hook arm  152 . The teeth  174  are in general vertical alignment with each other. However, other configurations of the teeth  174  are possible without departing from the scope of the invention. 
         [0050]    In this embodiment, the mounting clips  110  are embedded in the panels  115  as the panels  115  are formed. Panels  114  have adhesive applied to facing surfaces. The panels  114  are moved together. As this occurs, the mounting clips  110  are positioned between the panels  114  such that the movement of the panels  114  together causes the mounting clips  110  to be captured between the panels  114 . As this occurs, the teeth  174  engage and pierce the panels  114 . Continued movement of the panels  114  toward each other causes the plate section  150  to be trapped between the panels  114 . In this position, the adhesive applied to the panels  114  flows through the openings  166  to provide a strong bond between the panels  114  and the plate section  150 . The alignment notches  168  are positioned proximate the top of the panels  114  to provide visual alignment as the panels and mounting clips  110  are joined together. 
         [0051]    The mounting hardware or mounting clips  110  cooperate with the support members  116  to mount the panels  114  to the support members  16  and indirectly to the ceiling. As shown in  FIG. 16 , the hook arm  152  of each respective mounting clip  10  is configured to wrap around a respective the support member  116 . Once the hook arm  152  is positioned on the support member  116 , the movable mounting section  158  is rotated or pivoted about the connection legs  160 , thereby allowing the mounting flange  162  to be moved proximate a vertical flange  138  of the support member  116 . As this occurs, the locating tab  167  may be inserted into a respective locating slot  137  to help properly position the mounting clip  110  relative to the support member  116 . With the mounting flange  162  positioned proximate the vertical flange  138 , a screw may be inserted into either the appropriate screw receiving opening  164 , thereby causing the mounting clips  110  to be securely fastened and positioned relative to the support members  116 . 
         [0052]    If the screw is loosened, the mounting clips  110  may slide freely along the support member  116 . This allows the mounting clips, and ultimately the panels  114 , to be positioned and repositioned in the appropriate location to achieve the desired acoustic properties or the desired aesthetics. 
         [0053]    As will be appreciated from all of the embodiments, different number of panels can be mounted in differing configurations to accommodate the acoustic and/or aesthetic characteristics desired. 
         [0054]    The mounting clips and mounting system allows for the panels to be removed and repaired/replaced if there is damage. There is no need to remove the mounting hardware or the mounting system in order to accomplish the repair/replacement. 
         [0055]    The mounting clips and mounting system also allow for the repositioning of the panels. This allows for the panels to be repositioned as the needs or space changes. 
         [0056]    The mounting clips and mounting system are also versatile. A wide range of materials and sizes of panels can be installed with the same hardware and same system, thereby reducing the need to change hardware. 
         [0057]    The exemplary clips can be used to hang panels from standard grid, U-profiles, I-beam carrying members, peaked roof bulb design and other such configurations. 
         [0058]    While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.