Patent Publication Number: US-2011067337-A1

Title: Concealed Ceiling Panel System

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a division of U.S. patent application Ser. No. 11/871,482, filed Oct. 12, 2007, which claims the benefit of the filing date of U.S. Provisional Patent Appln. Ser. No. 60/852,044, filed Oct. 16, 2006. 
    
    
     FIELD AND BACKGROUND 
     The present invention relates to a suspended ceiling system and, more particularly, a ceiling panel adapted for use in a curved suspended ceiling system in which the suspension grid is substantially concealed from view by the ceiling panels and in which the panels can be shipped in a flat configuration. In one aspect of the invention, the ceiling panel includes tabs formed integrally therewith for attaching the ceiling panel to the suspension grid. In a second aspect, a clip is provided for securing the ceiling panel to a suspension grid. 
     Curved suspended ceiling systems are becoming increasingly popular. An exemplary curved suspended ceiling system is shown in our co-pending U.S. application Ser. No. 11/257,726, filed Oct. 25, 2005 (U.S. Publication No. 2006/0101764), which is incorporated herein by reference. This application discloses a unique curved suspension grid system in which the main runners are secured to a plurality of primary carriers that are oriented transversely to the main runners and extend substantially the width of the suspended ceiling. 
     As shown in the referenced application, the ceiling panels are supported directly on the top surfaces of the flanges of the main runners, as is typical in many suspended ceiling systems, and are secured in place by hold-down clips that are placed over the reinforcing bulb of the runner. However, it is sometimes desirable, usually for aesthetic reasons, to disguise or hide the supporting grid system for the panels. While this has been done for flat ceiling grids, the problems of creating a curved ceiling panel system that substantially conceals the support grid system have not been adequately addressed before the present invention. 
     SUMMARY OF THE INVENTION 
     The present invention comprises a novel flexible ceiling panel preferably formed from sheet metal, such as aluminum sheet. Each ceiling panel has a generally rectangular shape (corresponding in width to the spacing between the main runners) and is formed with a hem on all four edges. 
     Two different approaches for securing the panels to the grid system are contemplated. In a first embodiment of the present invention, a series of bendable tabs are formed integrally with the hem of the panel. To secure the panel to the associated grid system, the tabs are folded upwardly and outwardly from the panel along two axes to secure the panel to the grid system. 
     In a second embodiment, a plurality of separate spring clips is used to secure the panel to the grid system. Each clip includes a first leg adapted to have at least a portion thereof received in the hem of the ceiling panel. A second leg extends generally perpendicularly from the first leg and includes a detent extending toward the first leg, the detent being adapted to secure the clip to the flange of the runner. In one embodiment of the clip, the detent is adapted to engage an edge of the flange of the runner. In a second embodiment, the detent is adapted to engage an upper surface of the flange of the runner. 
     In a further aspect of the clip, the clip may include an angled segment extending from the second leg having a free end that is adapted to engage the flange of the runner during installation of the ceiling panel into the support grid. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of a ceiling panel according to a first embodiment of the present invention. 
         FIG. 2  is a fragmentary view of the ceiling panel of  FIG. 1 , enlarged to show detail. 
         FIGS. 3 and 4  are fragmentary perspective views illustrating the process for securing the ceiling panel of  FIG. 1  to a grid member or runner. 
         FIG. 5  is a cross-sectional view taken along line  5 - 5  in  FIG. 4  showing the ceiling panel of  FIG. 1  secured to a grid member. 
         FIGS. 6 ,  8  and  10  illustrate a clip for securing a hemmed ceiling panel to a grid member, with  FIG. 6  being a perspective view showing the relationship between the clip, the ceiling panel and the grid member,  FIG. 8  being a cross-sectional view taken along line  8 - 8  of  FIG. 6 , and  FIG. 10  being a perspective view of the clip. 
         FIGS. 7 ,  9  and  11  illustrate a variation of the clip of  FIGS. 6 ,  8  and  10  for securing a hemmed ceiling panel to a grid member. 
         FIG. 12  is a perspective view of a tool designed to assist in removal of a ceiling panel secured to a grid member by the clip of  FIGS. 7 ,  9  and  11 . 
     
    
    
     DETAILED DESCRIPTION 
     With reference to the accompanying drawings, the basic construction of a flexible ceiling panel  10  in accordance with the present invention is shown. Specifically, the panel  10  is made from sheet metal, and preferably from aluminum sheet of an aluminum alloy such as 3003H-14 or 3105 aluminum alloy. The panel  10  is typically 24 inches in width to match a standard grid module. However, a 30-inch width is also possible. The panel  10  may be perforated to improve acoustical performance. Additionally, acoustical materials (such as non-woven matt and insulation pads, rolls or batts) can be added to the back side of the panel  10  to improve sound absorption and reduce sound transmission. 
     The panel  10  has an edge perimeter comprising a hem  12  formed by folding the edges of the panel  10  back on themselves on all four sides. A preferred width for the hem is 0.472 inches, although other widths may be selected without departing from the invention. The panel hem design allows for the panel to curve to adapt to the profile of the suspension grid. The panels can conform to varying convex and/or concave contours in a single panel, with lengths up to 12 feet being contemplated, depending upon handling limitations. 
     With reference to  FIGS. 1-5 , a plurality of tabs  14  are formed integrally with the hem  12  spaced at intervals about the perimeter of the panel. As illustrated, the tabs  14  are generally rectangular in shape and have an overall dimension of 1½ inches by 11/16 inches, although other shapes and dimensions may be used. Each tab  14  is bendable relative to the hem  12  along a first axis to an angle of approximately 90° with respect to the panel  10 . A minor portion  14   a  (measuring approximately ½ inch by 11/16 inch) of each tab  14  is bendable along a second axis at an obtuse angle with respect to the major portion  14   b  of the tab  14  to provide the portion of the tab that engages the flange  17   a  of the runner  17 . The tab  14  is provided with slots or cutouts  16  along the first and second axes that facilitate bending of the tab as described above, although other techniques for predisposing the clip to bend at the desired locations may be used, such as pre-creasing the tab  14  along the first and second axes. 
     The panels  10  are shipped with the tabs  14  unbent, as shown in, e.g.,  FIGS. 1-3 . With reference to  FIGS. 4 and 5 , the panels  10  are secured to a grid member or runner  17  by first partially bending the tabs  14  along the first axis to help guide the panel  10  into the grid opening from below. Then, after the panel  10  is in position in the grid opening, the tabs  14  are bent along the second axis so that the minor portion  14   a  thereafter engages the back side of the horizontal flange  20  of the runner  17 . 
     With reference to  FIGS. 6-11 , a second system for securing the ceiling panel  10  to the grid system is shown. In this system, a hemmed sheet metal panel  10  is also provided. However, instead of having tabs being formed integrally therewith, the hems  12  include pre-punched holes  22  (best seen in  FIGS. 6 and 7 ) at spaced intervals that cooperate with a clip, generally designated  24 , to locate and appropriately space the clips and to secure the clips to the panel. 
     The clip  24  is generally L-shaped, with a first or lower leg  26  having a tab  28  being bent upwardly therefrom that is of a size and shape so that it can be received in the pre-punched hole  22  in the hem  12 . A second, longer leg  30  of the clip includes a spring tongue or detent  32  that extends generally toward the first leg  26  of the clip. With reference to  FIGS. 6 ,  8  and  10 , the free end  33  of the detent  32  extends toward the edge of the panel  10 , when the clip  24  is installed thereon, with an intermediate portion of the detent  32  being curved or bowed so as to overlie the flange  17   a  of the runner  17 . During installation of the panel into the grid, the curved portion of the detent  32  pulls the panel  10  upwards and holds the panel hem  12  against the face of the grid. The clip  24  also includes an upper angled portion  34  that allows the panel to be initially installed below the face of the grid, with the free end  36  of the angled portion resting on the flange of the runner, thus allowing the panels  10  to be installed without the clip  24  interfering with the reinforcing bulb of the runners in the grid. 
     The panels secured to a grid by means of the clip  24  of  FIGS. 6 ,  8  and  10  can be removed or demounted without a special tool by simply pulling downward at the edge of the panel and inserting a screw driver or bladed tool at the edge. By prying downwardly, the detent  32  can be disengaged from the flange of the runner and the panel lowered so that the free end of the upper angled portion  34  of the clip  24  rests on the flange of the runners. Final demounting of the panels is then accomplished by bending the vertical leg  30  by applying finger pressure to provide clearance between the angled portion  34  of the clip  24  and the flange  17   a  of the runner  17 . 
     Alternatively, and as illustrated in  FIGS. 7 ,  9  and  11 , the spring tongue or detent  32  may be shortened so that it extends over the inner edge of the hem. When the panel is installed, using this clip, the free end  33  of the detent  32  engages the upper surface of the flange  17   a  of the support runner  17 . As such, the spring clip  24  locks the panel in place, clamping the flange  17   a  of the grid between the detent  32  and the ceiling panel  10 . Consequently, a special tool is required to remove a panel utilizing this clip embodiment, such as the tool  40  shown in  FIG. 12 . The tool  40  has a working end  42  that is inserted between the hem of the panel and the bottom of the flange of the runner and then slid along the edge thereof to disengage the detent  32  from the top of the flange. 
     Thus, a system has been provided for securing a ceiling panel to a grid system in a manner that conceals the grid system from view. While the inventions disclosed in the present application are intended to be used with a curved suspension grid, they may also be used with a standard flat suspension grid without departing from the invention.