Abstract:
A paneling system for ceilings of a building structure in which the panels are suspended by hook shaped flanges, on opposite sides of each panel from flat arms of L- or Z-shaped panel carriers or support rails. One flange of each panel extends over the flange of a neighboring panel atop the horizontal arm of a panel carrier.

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATIONS 
   This application is a non-provisional patent application which claims priority to European Patent Application No. 02078119.1, filed 30 Jul. 2002. The European Application No. 02078119.1 is hereby incorporated by reference as thought fully set forth herein. 
   BACKGROUND OF INVENTION 
   1. Field of Invention 
   This invention relates to a paneling system for ceilings of a building in which panels are suspended by hook-shaped flanges, on opposite sides of each panel, from flat arms of L- or Z-shaped panel carriers or support rails. This invention particularly relates to ceiling panels with hook-shaped flanges, one flange of each panel extending over the flange of the neighboring panel atop the horizontal arm of a panel carrier. 
   2. Description of Known Art 
   Such paneling systems are described in DE 1 934 185, FR 1 203 394, and DE 84 37 592 U. For example, DE 1 934 185 describes: a plurality of conventional, horizontal spaced apart, parallel, panel carriers (1), each having a horizontal arm with an upstanding free end (2), so that the arm forms an upwardly-open U-shaped channel; and a plurality of adjacent, horizontally-extending, ceiling panels (3), each panel having a hook-shaped flange (4, 5) on each horizontally opposite side, forming a downwardly-open U-shaped channel above the bottom of the panel. One hook-shaped flange (5) of each panel (3) has a horizontally narrow, inwardly-extending top portion (7) and, at its free end, an inwardly- and downwardly-extending rim or edge (8), and the other hook-shaped flange (4) has a horizontally longer, outwardly-extending top portion (6) and, at its free end, a downwardly- and inwardly-extending rim (9, 10). The narrow flange (5) is provided under the longer flange (4) when adjacent panels (3) are installed with their flanges overlying the arm of a carrier, between the adjacent panels, and overlying the upstanding free end (2) of that carrier&#39;s arms. 
   SUMMARY OF INVENTION 
   In accordance with this invention, a ceiling paneling system, is provided with panels having improved hook-shaped flanges on opposite sides of the panels and panel carriers with improved arms adapted to hold the panels&#39; flanges, so as to enable easy installation and removal of individual panels. The paneling system comprises:
         a plurality of adjacent, longitudinally-extending panels: each panel having a pair of hook-like flanges on longitudinally-opposite sides; each hook-like flange forming a downwardly-open U-shaped channel above the bottom of the panel; a first hook-like flange of each panel having an inwardly-extending first top portion and, at its free end, a downwardly-extending first rim; a second hook-like flange of each panel having an outwardly-extending second top portion and, at its free end, a downwardly-extending second rim; the second top portion being of substantially the same length, but slightly longer, than the first top portion; and the first rim being longitudinally spaced away from an adjacent side of the panel; and   a plurality of longitudinally spaced apart, parallel panel carriers, each carrier having a longitudinally-extending arm with an upstanding free end forming an upwardly-open U-shaped channel; both the first top portion of a first flange on one longitudinal side of a first panel and the second top portion of a first flange on one longitudinal side of a first panel and the second top portion of a second flange on the opposite longitudinal side of an adjacent second panel being atop the arm of the carrier to attach the first and second panels to the carrier; the second top portion being atop the first top portion.
 
Preferably, the first rim on the first flange of each panel comprises a downwardly-extending locking member with a downwardly and outwardly angled surface facing the adjacent side of the panel. It is also preferred that an arm of each carrier comprises an upwardly-extending locking lug that is longitudinally spaced away from the upstanding free end of the arm; the rims of the first and second panel, attached to the carrier, being on longitudinally opposite sides of the locking lug and preferably contact the upper surface of the arm.
       

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Further aspects of the invention will be apparent from the detailed description below of a particular embodiment and the drawings thereof, in which:
           FIG. 1  is a vertical cross-section of a ceiling panel of a paneling system according to the invention;     FIG. 2  is a vertical cross-section of a panel carrier of a paneling system according to the invention;     FIG. 3  is a vertical cross-section of an assembled paneling system of the invention; and   FIGS.  4 . 1 - 4 . 4  are schematic representations of how the paneling system of  FIG. 3  can be assembled.       

   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1  shows a conventional, longitudinally-extending, preferably rectangular ceiling panel  1  for an interior ceiling of a building. A plurality of such panels  1  can be lain side-by-side to cover a ceiling with the paneling system of this invention. The panel  1  is a metal skin sandwich panel with the top metal skin layer  3 , a bottom metal skin layer  5  and a core layer  7  extending between the top and bottom skins. The bottom skin  5  is visible when the panel  1  is mounted in a ceiling. The core  7  is preferably a honeycomb material but can be any other core material or even several stacked layers of different core materials. The panel  1  can be an acoustic panel, where the bottom skin  5  is perforated. The panel  1  is preferably rectangular and has a front side (not shown), a back side (not shown), a left side  9  and a right side  11 . 
   Longitudinally opposite sides  9 ,  11  of the panel  1  are adapted for attaching the panel to one of the panel carriers (shown in  FIG. 2 ) of the paneling system of this invention. In this regard, left and right mounting profiles  13 ,  15  are provided on the panel, preferably by adhesively attaching them respectively to the left and right sides of the core  7 . In this regard, the left mounting profile  13  includes a left profile connector  21 , with a hollow rectangular cross-section, on the left side  9  of the core  7 , and the right mounting  15  includes a right profile connector  22 , with a hollow rectangular cross-section, on the right side  11  of the core. In order to facilitate the attachment of the profile connectors  21 ,  22  to the panel sides  9 ,  11 , portions of the core  7  are removed from these sides to make room for the profile connectors which then take the place of the removed core portions. The mounting profiles  13 ,  15 , particularly their profile connectors  21 ,  22 , preferably have a lateral length (not shown) and the height that are the same as the panel  1 . It is also preferred that the bottom skin  5  extends further longitudinally than does the top skin  3  on both sides  9 ,  11 , so that the bottom skin  5  can be adhesively attached to, and cover, the bottom and upstanding sides of the mounting profiles  13 ,  15 . In this way, the bottom of the panel  1 , that is visible when the panel is mounted, is always covered with the bottom skin  5 , and the core  7  does not show. It is also preferred that the top of the left and right profile connectors  21 ,  22  is also at least partially covered by the top skin  3  and that the top of the core  7  is completely covered by the top skin. 
   As seen from  FIGS. 1 and 3 , the left mounting profile  13  also includes a first or left, hook-like flange  23  forming a downwardly-open U-shaped channel above a longitudinally-extending support member  25  of the left profile  13 . The support member  25  connect the left profile connector  21  with the left flange  23 . In this regard, the left profile connector  21  preferably includes a left wall  21 A, a right wall  21 B, a top wall  21 C and a bottom wall  21 D, and the support member  25  is preferably integral with the bottom wall  21 D. 
   As also seen in  FIGS. 1 and 3 , the left flange  23  has; an upstanding left side wall  27 , the left side of which is preferably covered by the bottom skin  5 ; and a left top wall  29  that is atop the upstanding left wall and extends to the right, horizontally and inwardly (i.e., towards the adjacent panel side  9 ), away from the left side wall  27 . Preferably, the left top wall  29  also extends to the left, horizontally and outwardly (i.e., away from the adjacent panel side  9 ), away from the left side wall  27  and over the width of the left side wall and an upstanding left end of the bottom skin  5 . A small downwardly-extending left outer rim  31  on the left end of the left top wall  29  holds securely the left end of the bottom skin  5  against the left side wall. At the right end of the left top wall  29  is a small downwardly-extending left inner rim  33  for locking the panel to a carrier. The left inner rim  33  has an inner surface  33 A, facing the adjacent side  9  of the panel, and an outer surface  33 B. The inner surface  33 A is preferably slanted downwardly and leftwardly (i.e., outwardly of the core  7 ). The left inner rim  33  is longitudinally spaced away from the adjacent left wall  21 A of the left profile connector  21  on the left side  9  of the panel to form a horizontal gap  34  in the left mounting profile  13  over the support member  25 . 
   As further seen from  FIG. 1 , the right mounting profile  15  also includes a second or right, hook-like flange  37  forming a downwardly-open U-shaped channel. The right, hook-like flange  37  is connected to the right side of the right profile connector  22 . In this regard, the right profile connector  22  preferably includes a left wall  22 A, a right wall  22 B which is preferably covered by the bottom skin  5 , a top wall  22 C which is integral with the right flange  37 , and a bottom wall  22 D. 
   As still further seen in  FIG. 1 , the right flange  37  has a right top wall  41  that extends to the right, horizontally and outwardly (i.e., away from the adjacent panel side  11 ), away from the top wall  22 C of the right profile connector  22 , and a depending left rim  43  that is adjacent the right wall  22 B of the right profile connector  22  and that holds securely the right end of the bottom skin  5  against the right wall  22 B. At the right end of the right top wall  41  is a small downwardly-extending right rim  45  for locking the panel to a panel carrier. Preferably, the right top wall  41  is not covered by the top skin  3 . 
   In accordance with this invention, the right top wall  41  of the right flange  37  extends to the right, horizontally and outwardly, away from the top wall  22 C of the right profile connector  22  by a distance that is the substantially the same, but slightly greater, than the distance that the left top wall  29  of the left flange  23  extends to the right, horizontally and inwardly, away from the left side wall  27 . Thereby, the right top wall  41  can completely cover left top wall  29  when the right top wall lies directly atop the left top wall when the flanges  23 ,  37  are used to mount a pair of panels  1  on a carrier. 
   Also in accordance with this invention, the right rim  45  of the right flange  37  extends downwardly from its right top wall  41  by a distance that is substantially the same, but slightly greater, than the distance that the left inner rim  33  of the left flange  23  extends downwardly from the right side of its left top wall  29 . Thereby, when the right top wall  41  lies directly atop the left top wall  29 , the bottom of the right rim  45  will be substantially horizontal with the bottom of the left inner rim  33 . 
   The mounting profiles  13 ,  15  are preferably made as extrusions that are mounted on the left and right sides  9 ,  11  of the panel  1 , adjacent its core  7 . However, the mounting profiles  13 ,  15  could also be integrally formed with the bottom skin  5  of the panel or with the core  7 . 
     FIGS. 2 and 3  show a preferred panel carrier  47  of the paneling system of this invention. A plurality of such carriers  47 , in parallel and spaced apart relationship, can be used to support a plurality of the panels  1  of  FIG. 1  to cover a ceiling with the paneling system of this invention. Depending on the type of ceiling or wall construction to be used with the panel  1 , the carrier  47  can be an elongated extrusion or a hook-like member. 
   As shown in  FIGS. 2 and 3 , the carrier  47  preferably has a conventional, generally L- or Z-shaped configuration, with; a horizontally-extending top flange  49 , to be connected to a ceiling or panel suspension system; a vertically-extending intermediate member  51 , the top of which is connected to the left end of the top flange; and a horizontally-extending bottom flange  53 , connected to the bottom of the intermediate member. The bottom flange  53  preferably extends horizontally and leftwardly away from the top flange  49  to a free left side  53 A. The top surface  53 C of the bottom flange  53 , on which a pair of panels  1  can be mounted, has: a vertically-extending locking lug  57 , between a carrier lug  55  and the intermediate member  51 . The carrier lug  55  has: a gentle left ramp  55 A extending downwardly and leftwardly towards the free left side  53 A of the bottom flange  53 ; a sharper, vertically downward or angled-back right wall  55 B; and a top wall  55 C, between them. The left ramp  55 A facilitates the installation of a panel  1  on the carrier  47 , even when the adjacent panel  1  is already in place as will be explained below. The height of the top wall  55 C of the carrier lug, above the top surface  53 C of the bottom flange  53 , is at least equal to the distance that the left inner rim  33  extends below the left top wall  29  of the left flange  23 , and the locking lug  57  preferably has a height above the top surface of the bottom flange that is at least equal to the distance that the right rim  45  extends below the right top wall  41  of the right flange  37 . Hence, the locking lug  57  is preferably higher than the carrier lug  55 , and this difference in height should be at least equal to the difference in the height of the right rim  45  and the left inner rim  33 . 
   Between the carrier lug  55  and the locking lug  57 , there is a first or left, upwardly-open U-shaped carrier channel  59 , adapted to receive the left inner rim  33  of the left flange  23  when a panel  1  is mounted on the panel carrier  47 . Between the carrier locking rim  57  and the upstanding intermediate member  51  is a second or right, upwardly-open U-shaped carrier channel  61 , adapted to receive the right rim  45  of the second flange  37  when a panel  1  is mounted on the panel carrier  47 . 
     FIG. 3  shows a carrier with a pair of adjacent ceiling panels of  FIG. 1 , mounted on the panel carrier of  FIG. 2 . The panels are the same, but for clarity, like parts of one panel have the same reference numerals as the panel of  FIG. 1  while the other panel has reference numerals greater by “100” than those of the panel of  FIG. 1 . 
   As shown in  FIG. 3 , the left top wall  29  of the left flange  23  of the left mounting profile  13  of one of the panels  1  is mounted on the carrier lug  55  of the bottom flange  53  of the panel carrier  47 . This was done by tilting the panel upwardly to the right and moving its left side  9 , so as to: i) insert the free end  53 A of the bottom flange  53  of the carrier  47  through the vertical gap  34  in the left mounting profile  13  of the panel, between the left inner rim  33  and the left profile connector  21 ; and ii) then hook the left flange  23  over the carrier lug  55 , so that the left inner rim  33  passes over the carrier lug  55  and past its right wall  55 B. As a result, the bottom of the left inner rim rests on the top surface  53 C of the bottom flange  53  in the left carrier channel  59 . 
   On top of the left top wall  29  of the left flange  23  in  FIG. 3  is the right top wall  141  of the right flange  137  of the right mounting profile  115  of the other panel  101 . The bottom surface of its right top wall  141  rests on the top surface of the left top wall  29  of the left flange  23  of the panel  1 . The left outer rim  31  of the left flange  23  of the panel  1  abuts the depending left rim  143  of the right flange  137  of the adjacent panel  101 . The bottom of the right rim  145  of the right flange  137  rests on the top surface  53 C of the bottom flange  53  of the carrier  47  in the second carrier channel  61 . 
     FIG. 3  clearly shows that the height of the left top wall  29  (i.e., the height of the upstanding left side wall  27 ) of the left flange  23 , above the support member  25 , is substantially more than the height of the carrier lug  55  to assure maneuvering height when installing the left side  9  of the panel  1 , before the right side  111  of the other panel  101 , on the bottom flange  53  of the carrier  47 . Also, the gap  34  in the left mounting profile  13  of the panel  1  is sufficiently wide horizontally, so that the left side  9  of the panel can be moved around the flange  53  of the carrier  47  to insert the flange&#39;s free end  53 A between the left top wall  29  and the support member  25  of the left mounting profile. Further, the slopes of the left ramp  55 A of the carrier lug  55  and the inner surface  33 A of the left inner rim  33  preferably allow the left inner rim  33  to ride easily upward along the left ramp  55 A when installing the left flange  23  of a panel  1  on the carrier  47 . In addition, the locking lug  57  of the carrier  47 , which provides a wall between both the left and right, carrier channels  59  and  61 , is preferably a bit higher than the carrier lug  55 . In this regard, the excess height of the locking lug  57  is preferably a little less or equal to the thickness of the right top wall  141  of the right flange  137 , thus ensuring that the right top wall contacts the whole horizontal length of the left top wall  29  when the right and left flanges are atop one another on the carrier&#39;s bottom flange  53 . 
   FIGS.  4 . 1 - 4 . 4  show a methods of mounting and dismounting a plurality of identical ceiling panels  1 ,  101 ,  201 , etc. of  FIG. 1  and on a plurality of parallel identical carriers  47 ,  147 , etc. of  FIGS. 2 and 3 , mounted on a ceiling. 
   Step 1. As shown in  FIG. 4.1 , a first panel  1  is mounted on parallel adjacent, first and second carriers  47 ,  147 . The first panel is first slightly tilted with its right side  11  extending upward, so that the first panel can then be placed between the two carriers. The bottom flange  53  of the first carrier  47  is then inserted through the vertical gap  34  in the left mounting profile  13  of the first panel. Then, the left flange  23  of the left mounting profile  13  of the first panel is hooked around the free end  53 A of the bottom flange of the first carrier, so that its left inner rim  33  is over the carrier lug  55  while the right side  11  of the panel is above the bottom flange  153  of the second carrier  147 . While hooking the first panel  1  over the carrier&#39;s free end  53 A, the left inner rim  33  rides upwardly and leftwardly along the left ramp  55 A of the carrier lug  55  to a position where the left inner rim  33  can subsequently descend into the left carrier channel  59  on the bottom flange  53  when the right side  11  of the first panel is moved downwardly until the first panel is horizontal. 
   Step 2. As shown in  FIG. 4.2 , the right side  11  of the panel  1  is subsequently lowered, and the right rim  45  of the right flange  37  rests in the right carrier channel  161  on the bottom flange  153  of the second carrier  147 . 
   Step 3. As shown in  FIG. 4.3 , a second panel  101  is subsequently mounted on the second carrier  147  and on a third carrier  247  by first lifting slightly the right flange  37  of the first panel from the bottom flange  153  of the second carrier  147  as shown in  FIG. 4.3 . Then, the second panel  101  is slightly tilted with its right side  111  extending upward, so that the second panel can then be inserted between the two carriers  147 ,  247 . The left flange  123  of the second panel  101  is then hooked around the second carrier&#39;s free end  153 A as described above in Step 1. In so hooking the left flange  123 , its left inner rim  133  and its left top wall  129  pass between the carrier lug  155  of the second carrier  147  and the right mounting profile  15  of the first panel  1 . 
   Step 4. As shown in  FIG. 4.4 , the right side  111  of the second panel  101  is subsequently lowered, so that the right rim  145  of its right flange  137  rests in the right carrier channel  261  of the bottom flange  253  of the third carrier  247  and the left inner rim  133  of its left flange  123  rests in the left carrier channel  159  of the bottom flange  153  of the second carrier  147 . Then, the right side  11  of the first panel  1  is lowered, so that the right top wall  41  of its right flange  37  rests atop the left top wall  129  of the left flange  123  of the second panel  101  and the right rim  45  of its right flange  37  rests in the right carrier channel  161  of the bottom flange  153  of the second carrier  147 . 
   Of course, these mounting steps can be repeated for more panels and panel carriers. These steps can also be reversed for easily dismounting any panels from the carriers, to which they are attached. 
   This invention is, of course, not limited to the above-described embodiments which may be modified without departing from the scope of the invention or sacrificing all of its advantages. In this regard, the terms in the foregoing description and the following claims, such as “right,” “left,” “front,” “back,” “vertically,” “horizontally,” “longitudinally,” “upper,” “lower,” “top,” and “bottom,” have been used only as relative terms to describe the relationships of the various elements of the panel and carrier of the ceiling paneling system of this invention. 
   For example, the left and right mounting profiles  13 ,  15  of panel  1  are preferably each made as one piece, but can also be made as separate pieces with separate profiles connectors  19 ,  21 , elongated supporting member  25  and hook-like flanges  23 ,  37 , which are subsequently attached. Moreover, the paneling system of this invention is also applicable to the walls of buildings and is not limited to their ceilings.