Abstract:
A free form ceiling panel for suspended ceiling systems that creates the appearance of moguls. The free form ceiling panels fit into a suspended ceiling grid. The free form ceiling is a grid system made up of curving tee members and preformed curved panels. The grid members curve in predefined radii into which formed panels are placed. The frame is formed from individual curved grid members that meet at their respective ends to form intersections. The grid members are rigid preformed members that are curved so that when interconnected a curve is formed.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to suspended ceiling systems and more particularly to a novel ceiling panel that is designed to create a sinusoidal free form ceiling structure. 
     PRIOR ART 
     Suspended ceiling systems typically include grid members that provide for oppositely extending ceiling panel support flanges. The grid members are interconnected to form a grid and are suspended from the structure of a building with wire hangers or rods. In these systems, the edges of the ceiling panels are installed by laying the panels in the grid opening created by the grid members. Once the ceiling panels are installed into the grid, a uniform ceiling surface is created. Suspended ceiling panels are manufactured from gypsum or slag wool fiber and are designed to conceal pipes, wiring and the like, while still allowing access to the concealed space above the ceiling. Typical ceiling panels are fabricated out of sound deadening and insulating material and are designed to meet fire safety codes. The acoustical panels are planar in appearance and do little to enhance a room&#39;s décor. The acoustical panels also may include surface impressions and markings to enhance their appearance. When the panels are installed in the grid, the overall appearance of the ceiling is a generally planar. Prior art panels do not provide for a ceiling system that creates a sinusoidal free form ceiling structure. 
     SUMMARY OF THE INVENTION 
     This invention may be described as a novel ceiling panel that is used with a corresponding grid system to create a sinusoidal free form ceiling structure. The panels, when installed in the grid system create the appearance of moguls and are designed to enhance the appearance of retail and office space that utilize suspended ceilings to conceal the building structure. The free form ceiling is a grid system made up of curving tee members and preformed curved panels. The grid members curve in predefined radii into which formed panels are placed. The frame is formed from individual curved grid members that meet at their respective ends to form intersections. The grid members are rigid preformed members that are curved so that when interconnected a curve is formed. Alternatively, a standard planar grid system with variable length extension posts attached to the grid can be utilized to secure the free form panels. The panels are square when viewed in plan view but have a curved cross-section about all or part of the panels. The panels can be fabricated out of plastic, metal, glass reinforced gypsum, woven or non-woven mesh or fabric and can be opaque or translucent. In order to fill in the openings created by the sinusoidal grid members, the panels are rotated until they fit into their respective opening. The preferred panels are designed so that the four corners of the panel all lie in the same plane, although the corners can be designed to lie in independent planes. A ring shaped escutcheon can be used at grid member intersections to create openings in the ceiling system so, for example, a lighting or sprinkler system can be installed. 
     These and other aspects of this invention are illustrated in the accompanying drawings, and are more fully described in the following specification. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the free form ceiling as seen from below of the present invention suspended by wire hangers; 
     FIG. 2 is a cross section of FIG. 1 taken along line  2 — 2  illustrating the grid members; 
     FIG. 3 is a cross section of FIG. 1 taken along line  3 — 3  illustrating the grid members; 
     FIG. 4 is a perspective view as seen from above of an alternate embodiment of the free form ceiling illustrating the use of a planar grid system incorporating variable length posts to suspend the panels; 
     FIG. 5 is a cross section of FIG. 4 taken along line  5 — 5  illustrating the panels suspended from the variable posts; 
     FIG. 6 is a cross section of FIG. 4 taken along line  6 — 6  illustrating the panels suspended from the variable length posts; 
     FIG. 7 is a perspective view of the alternate embodiment of the free form ceiling illustrating the variable length posts suspending the panel from a planar grid; 
     FIG. 8 is an exploded view of the panel and its connection to a post; 
     FIG. 9 is an exploded view of the panel illustrating an alternate panel connecting mechanism; 
     FIG. 10 is a perspective view of the free form ceiling of the present invention illustrating the use of an escutcheon at an intersection to allow for the installation of electric lighting; 
     FIG. 11 is an exploded view of an escutcheon connected at a grid intersection; 
     FIG. 12 is a perspective view of the free form ceiling illustrating one type of connection of the panel to the grid; 
     FIG. 13 a  is a cross-section of FIG. 12 taken along line  13 — 13 ; 
     FIG. 13 b  is a cross-section of the free form ceiling showing the grid member and an alternate panel edge configuration; 
     FIG. 14 is a cross-section of an alternate ceiling panel of the present invention; 
     FIG. 15 is a cross-section of an alternate ceiling panel of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the present invention will be described fully hereinafter with reference to the accompanying drawings, in which a particular embodiment is shown, it is understood at the outset that persons skilled in the art may modify the invention. Accordingly, the description which follows is to be understood as a broad informative disclosure directed to persons skilled in the appropriate arts and not as limitations of the present invention. 
     FIG. 1 illustrates a portion of an assembled free form ceiling system  10  suspended by wire hangers  12 . The free form ceiling system  10  is comprised of curved grid members  14  that are interconnected to form a grid structure  16 . The grid members  14  are arranged to form openings  18  sized to receive curved ceiling panels  20 . The grid members  14  are suspended from the building structure by the wire hangers  12  or other supporting devices. 
     The grid members  14 , as shown in FIGS. 1-3, have a tee shaped cross section and include a horizontally oriented base member  22 , a bulb portion  23  and a vertically oriented bridge member  24  that interconnects the base member  22  to the bulb portion  23 . The base member  22  is connected to and perpendicularly oriented to the bridge member  24  and preferably has a width of {fraction (9/16)} of an inch. The grid members  14  include a plurality of openings  25  and slots  26  to allow for the attachment of hanger devices  12  and the connection to other grid members  14 . The slots  26  are spaced apart 24 inches on center. The grid members  14  are fabricated out of a die formed aluminum or steel and are curved during a secondary manufacturing process. The grid members  14  are curved into a low amplitude wave. The grid members  14  are manufactured in three preferred lengths, 8 feet, 4 feet, and 2 feet, although other lengths may be used. On a constructed grid  16 , the main grid members  14  are typically longer than the cross grid members  14 , which complete the grid  16 . The curved sections create a plurality of crests  29 , and valleys  28 , as shown in FIG.  2 . Each section of the grid members  14  include a first end  27  and a second end  30 . The ends  27  and  30  are adapted to allow for the attachment of grid clips  31  so that one grid member  14  can be connected to the end of a second grid member  14 . 
     To created the grid structure, a row of parallel evenly spaced grid members  14  are suspended by the wire hangers  12 , as shown in FIG.  1 . The grid members  14  are arranged so that the elevation of the crests  26  and valleys  28  in each row are equal. Each row of grid members  14  are dimensioned to accommodate the size of the curved ceiling panels  20 . To accommodate a 2-foot by 2-foot ceiling panel, the grid members  14  would be spaced apart 2 feet on-center. The free form grid structure  16  also includes a second set of grid members  14  that are perpendicularly oriented in relation to the first set of grid members  14  to create the opening required for suspending the panels  20 . 
     The free form ceiling panels  20  have a square appearance when viewed in plan view but have a curved cross-section about all or part of the panel, when viewed in cross-section. The panels are preferably square but other geometric shapes can be used such as rectangular and triangular. The panels  20  can be fabricated out of plastic, metal, glass reinforced gypsum, woven or non-woven mesh or fabric and can be opaque or translucent. Plastic panels, typically polycarbonate, are thermoformed and metal panels are pressed to form the desired shape. In order to fill in the openings  18  created by the grid members  14 , the panels are rotated until they fit into their respective opening  18 , as shown in FIG.  1 . The panels  20 , if designed with equal crest and valley radius, have the four corners of the panel all lying in the same plane. Variations in the radius of the crest  33  and valley  35  of the panels  20  vary the orientation of the corners  37  and  39  of the panels  20  with respect to each other as shown in FIGS. 14 and 15. For square or rectangular panel systems, a repeating grid configuration allows one panel design to be used for filling an entire grid structure. The panels  20  include four edges  32 ,  34 ,  36  and  38 , wherein each edge is supported by the base  22  of the grid members  14  as shown in FIG.  1 . The panels  20  also include four corners  40 ,  42 ,  44  and  46  that can have end points all lying in the same plane. The edges  32 ,  34 ,  36  and  38  form low amplitude waves and are designed so that a single panel design can be used to fill the various grid openings  18 . The panels  20  are secured to the grid using individual clips  47  that are installed over the bulb portion  23  to hold the panels  20  into position. Alternatively, integral panel clips  47  that extend outwardly from the edges  32 ,  34 ,  36  and  38  of the panels  20  can be used to secure the panel to the bulb portion  23  to position the panel  20  tightly along the base member  22  of the grid  14  as shown in FIGS. 12,  13   a  and  13   b.    
     FIG. 4 illustrates an alternate embodiment of the free form ceiling system  10  wherein a planar ceiling grid system  48  is utilized to support the panels  49 . The grid system  48  is supported to a building structure by wire hangers  50 , rods or other support devices. The grid system  48  is formed from linear grid members  52  that are positioned in a first set of evenly spaced rows that are perpendicularly oriented to a second set of evenly spaced rows to form a plurality of grid openings  54  and grid intersections  56 . Extending downwardly from the grid intersections are a plurality of extension members  58 . The extension members  58  are fabricated in three lengths a long member  60 , an intermediate length member  62  and a short member  64 . 
     FIG. 5 illustrates a cross-section  5 — 5  taken of FIG. 4 illustrating the linear grid members  52  spanning above the panels  49 . The panels  49  are connected to the grid members  52  by the intermediate length and the short extension members  62  and  64 . The extension members  58  are positioned at each of the grid intersections  56  and are adapted to connect the corners of four separate panels  49 . To properly attach the panels  49  to the grid system  48 , each panel  49  is connected with extension members  58 . 
     FIG. 6 illustrates a cross-section  6 — 6  taken of FIG. 4 illustrating the linear grid members  52  spanning above the panels  49 . The panels  49  are connected to the grid members  52  by the intermediate length and the long extension members  62  and  60 . The extension members  58  are positioned at each of the grid intersections  56  and are adapted to connect the corners of four separate panels  49 . 
     FIG. 7 illustrates the free form ceiling panel  49  suspended from a linear grid system  48 . The extension members  60  and  62  include tube shaped member  67  that includes an upper end  66  and a lower  68 . The tube shaped member  67  is preferably fabricated from aluminum or steel square tube stock, but other materials can be used known to those skilled in the art. The upper end  66  includes a grid clip  70  that allows attachment of the extension members  60 ,  62  and  64  to the base member  22  of the grid members  52 . The lower end  68  of the extension members  60 ,  62  and  64  include a connector plate  72  that allows for the attachment of the suspension panels  49 . The short extension members  64  do not require a tubular shaped member  67  since the grid clip  70  mounts directly to the connector plate  72 . 
     FIGS. 8 and 9 illustrate two variations in the connector plates  72  and  80  to allow for connection of the panels  49 . The first connector plate  72 , illustrated in FIG. 8 utilizes a square plate  72  with four threaded apertures  78  to allow the panel  49  to be attached by a fastener  76 . The fastener  76  passes through an aperture  74  in the corner of the panel  49  and threadably engages the aperture  78 , locking the panel  49  to the extension member  60 . The second connector plate  80  is also connected to the lower end  68  of the extension member  60  and includes a spring clip channel  86  that is adapted to accept spring clip  82 . The spring clip  82  is mounted to a side  84  of panel  49  (as shown in FIG.  9 ). The spring clip arrangement allows the bottom surface  88  of the panel  49  to be void of fasteners to create clean, uninterrupted surface when viewed from below. The spring clip  82  is a V-shaped member that includes two upwardly extending support wires  90  and is connected at its based to a support pin  92  on the side  84  of the panel  49 . The support wires  90  are flared outward to provide a biasing force to retain the panel  49  in the closed position. The upper ends of the support wires  90  include retaining ends  94  to support the panel  49  when it is in the open position. To lower the panel  20 , a downward force is applied to the panel  20  to overcome the biasing force of the support wires  90 . The panel  49  will continue to move downward until the retaining ends  94  contact the connector plate  80 . To remove the panel  20 , the support wires  90  are squeezed so that the retaining ends  94  clear the spring clip channel  86 . 
     The panels  49  can also be suspended without the use of a grid by connecting the panels  49  to the short extension members  64  and suspending the extension members  64  from the building structure with hangers  12 . Also, the panels  64  can be interconnected with clips and suspended to the building structure by attaching the hangers  12  to the panels  49 . 
     FIGS. 10 and 11 illustrate a ring-shaped escutcheon  96  positioned at the intersection of four grid members  14 . The escutcheon  96  allows for lighting  98 , sprinkler heads or other items that need to pass through the ceiling system  10 . The opening is formed by using four grid members  14  that are slightly shortened to accommodate the escutcheon  96 . Clips  100  are installed at the ends  27  of the grid members  14 , to provide an attachment surface for the escutcheon  96 . The escutcheon  96  is comprised of a ring portion  102 . The cup portion  104  is connected to the clips  100  by use of fasteners  108 . The panels  20  are modified by removing a corner section creating an opening  110  in the panel. 
     Various features of the invention have been particularly shown and described in connection with the illustrated embodiment of the invention, however, it must be understood that these particular arrangements merely illustrate, and that the invention is to be given its fullest interpretation within the terms of the appended claims.